Process for the controlled introduction of oil into food products

ABSTRACT

A process for the application of a predetermined amount of oil to food pieces comprises: (a) providing or receiving a plurality of cut or shaped food pieces; (b) applying an oil-water emulsion to the food pieces for a time sufficient to provide a predetermined amount of oil to the food pieces and so that the food pieces have an initial moisture level after applying the oil-water emulsion; and (c) reducing the initial moisture level, in the absence of frying in oil, to a moisture level of from about 0.2 to about 80% by weight to provide a cooked food product, comprising said predetermined amount of oil, wherein step (c) does not comprises frying the food pieces in hot oil.

This application is a continuation of U.S. patent application Ser. No.15/808,707, filed Nov. 9, 2017, which is a continuation of U.S. patentapplication Ser. No. 15/465,258, filed Mar. 21, 2017, which is acontinuation of U.S. patent application Ser. No. 14/816,784, filed Aug.3, 2015, which is a continuation-in-part of U.S. patent application Ser.No. 14/444,731, filed Jul. 28, 2014, which is a divisional applicationof Ser. No. 14/055,994, filed Oct. 17, 2013; now U.S. Pat. No.8,980,393; which is a continuation of Ser. No. 14/054,323, filed Oct.15, 2013, now U.S. Pat. No. 8,962,094; which is a continuation of Ser.No. 12/090,845, filed Jul. 6, 2009, now U.S. Pat. No. 8,715,760; whichis a 371 application of PCT/US2006/038963, filed Oct. 4, 2006, whichclaims priority to U.S. Provisional Patent No. 60/723,880, filed Oct. 4,2005, and to U.S. Provisional Application No. 60/820,743, filed Jul. 28,2006; and the present application is a continuation-in-part of U.S.patent application Ser. No. 14/613,577, filed Apr. 2, 2015, which is acontinuation application of Ser. No. 12/090,842, now U.S. Pat. No.8,980,350; which is a 371 application of PCT/US2006/038966, filed Oct.4, 2006, which claims priority to U.S. provisional patent applicationNo. 60/723,881, filed Oct. 4, 2005 each of which is incorporated hereinby reference in its entirety.

BACKGROUND OF THE INVENTION

The present invention relates generally to methods of making low-fat,fat free, or full-fat food products, and products made according to themethod, in which food pieces are subjected to a controlled applicationstep of oil and can be subjected to enzyme and/or cation treatment,blanching and/or specific cooking and/or drying techniques, to providefor snack food products having the texture, flavor, and othercharacteristics of conventional full-fat fried products.

Snack food products typically are made by frying sliced vegetable piecesin hot oil so that the moisture content of the sliced food pieces isreduced to a very low level and fat content is raised exponentially.Such products generally have a characteristic crispness that addssignificantly to its organoleptic desirability. Fried potato or applechips prepared using conventional methods generally have a fat contentfrom about 30 percent to about 40 percent by weight, a percentage of fatthat is considered by some to be unhealthy if these types of productsare broadly substituted for low-fat foods and consumption is significantover time. While such products are accepted in the marketplace,consumers' desire to lower their fat consumption, limits thisacceptance.

Furthermore, the conventional methods generally used, require thesefoods to be fried at high temperatures that can result in the productionof potentially deleterious by-products. Reports of such by-products inrecent years have led to general concerns about both fried and bakedfoods, especially those containing high amounts of fats andcarbohydrates. Reports of acrylamide formation, generally in proportionto the degree of browning of foods high in fats and carbohydrates, haveraised significant concerns within the food industry, the potential forharmful effects of this particular processing by-product.

To address some of these concerns, efforts have been made to reduce theamount of fat in such snack food products, and more recently, to findways to minimize formation of potentially deleterious substances such asacrylamide and the like.

In recent years, “light” chips have been made using synthetic oils/fatthat is substantially non-digestible and consequently non-absorbable bythe human body, e.g. OLESTRA™. These products have received limitedacceptance due in part to off-flavors perceived by some reports ofdetrimental gastrointestinal side effects and an FDA requirement of awarning label on such products, providing information that such fatsubstitutes may cause gastrointestinal side effects such as loose stoolsand abdominal cramping and/or the inhibition of absorption of somenutrients.

While products such as potato and apple chips are typically made usingconventional frying methods, snack food products made with othernutritionally beneficial vegetables and fruits such as carrots, squash,parsnips, yuccas, pears, and the like have not successfully entered themarket substantially due to the lack of effective processing methods.

There have been numerous efforts in the past to reduce the amount of fatin snack foods such as potato chips, via various processing means. Thesemethods have achieved limited success in reducing fat content whilestill achieving desirable taste. One example is by conditioning surfacesof the food pieces prior to frying in oil in order to reduce oilabsorption during frying.

Another example of reducing fat content is preparing the food pieceswith full-fat or near full-fat content through conventional fryingmethods, and to subsequently remove some of the oil, such as viacentrifugal force or superheated steam. These methods tended to becomplicated and expensive, are known to damage or otherwise undesirablyalter the final product, and would typically remove only a smallfraction of the oil, and less than the amount of oil removal desired.

Yet another method of reducing oil content involved alternative methodsof drying the food pieces without frying in oil, such as microwaveheating, convection ovens, fluidized bed dryers, and the like. Oil orfat was typically applied in a separate step, such as a spraying step,in order to achieve a desired flavor while providing for some controlover the amount of fat applied to the food pieces. However, ideally thefood pieces should be in a monolayer to ensure even application of theoil, which can be difficult and expensive. Alternatively, the oil can beapplied in a spray drum, which can evenly distribute the oil, butgenerally must be applied after drying, which can result in lessdesirable taste and texture than when the oil is applied before drying.

Because of the difficulties in spraying the oil, oil can also be appliedby immersing the food pieces in the oil without cooking the food pieces.It is considerably more difficult to control the oil uptake onto or intothe food pieces through oil immersion. For example, the parameters thattend to affect oil uptake the most are immersion time and temperature.Low-temperature oil has a higher viscosity, and thus tends to moreeasily adhere to the food pieces, while higher-temperature oil is lessviscous, and less likely to adhere, but will also tend to be more likelyto penetrate the surface of the food pieces, resulting in higher oiluptake. A food piece that has been fully immersed in oil of anytemperature for any length of time will emerge with a minimum carry-overof oil that adheres to the surface of the food piece. For example, forpotato slices the carry-over can be 5-12% of the weight of the slice,depending on slice thickness. After subsequent drying the percentage ofoil by weight can be comparable to, or only modestly below, the oiltake-up via traditional frying methods. Excess take-up of oil via theimmersion method can be partially controlled by a subsequent oil removalstep, such as gravitational draining, water sprays, or pressurized airjets. These methods, however, can also be difficult because of the needto monolayer the food pieces to ensure even removal of oil. The oilremoval also adds another step to the process.

Roan (U.S. Pat. No. 4,058,631) discloses a method of making fried foodin which raw food product is treated with an aqueous solution of anenzyme, such as alpha amylase, for a period of time sufficient for theenzyme to penetrate and coat the surface of the food, and thereafter thefood product is deep fried. Roan indicates that when the surface of araw, starchy food product is coated with an aqueous solution of alphaamylase prior to frying, less fat is absorbed in the food during fryingthan occurs without the enzyme treatment, and the flavor of the friedfood is improved.

Dreher et al. (U.S. Pat. No. 4,756,916) discloses a process forproducing low oil potato chips comprising washing potato slices with anaqueous solution, and applying oil to the washed slices to coat theslices with oil. The oil-coated slices are arranged as a monolayer on anendless conveyor belt, blanched at a temperature between about 160° F.and 212° F., and then baked at a high temperature of at least about 390°F. but below the smoke point of the oil, to partially dry the slices byreducing the aqueous moisture content of the slices to about 10-20% byweight. The partially dried slices then are further baked at a lowertemperature of about 290°-320° F. to finish drying the slices byreducing the aqueous moisture content of the slices to about 2% byweight or less, to produce a product having an oil content of betweenabout 10-25% by weight.

Laufer (U.S. Pat. No. 5,292,540) discloses a process for preparingpotato chips comprising the steps of washing potatoes to remove foreignmatter from the skin thereof, cutting the potato into thin slices,baking the slices for a period of about six to twelve minutes within atemperature range of about 250 to 500° F., and heating the slices in amicrowave oven for about two to seven minutes.

Yamashita (U.S. Pat. No. 5,312,631) discloses a method for preventingcut pieces of agricultural products from sticking to each other duringthe steps of drying and cooking, which includes washing the cut pieceswith, or immersing the same in, a solution of an amylolytic enzyme, oran acidic or alkaline aqueous solution. The cut pieces are blanchedprior to enzyme treatment.

Zussman (U.S. Pat. No. 5,370,898) discloses a cooking process for foodchip products that does not involve oil-based cooking. Food slices arewashed with water to remove extractable surface starch, multi-layered,transported to an oven, and baked in a fluidized bed of hot air orsteam. The baking process is a multi-step process, whereby the foodslices are exposed to a higher pressure in a first zone for severalminutes to ensure that the individual food pieces are separated. Thepressure is then lowered in a second zone for a second period of time.Similarly, in a third zone the pressure is reduced for a predeterminedperiod of time to finish cooking the food products. Thereafter the chipsare air-dried or finished in a dryer.

Lewis et al. (U.S. Pat. No. 5,441,758) discloses the preparation oflow-fat or fat free potato chips or straws by a process comprisingslicing potatoes to form slices or straws, blanching the sliced potato,and treating the slices during or after blanching with a hightemperature amylase enzyme to prevent later sticking together of slicesduring processing. The slices are thereafter dehydrated at 158° F.-212°F. content of 9% or lower. The dehydrated potato pieces are thenrehydrated to a moisture content of 12% to 30%, and thereafter toastedto about 2% moisture at a temperature of 140° C. to 220° C. The use of ahigh temperature amylase is required so that the enzyme remainseffective during processing, and is not inactivated by the blanchingstep. Lewis et al. discloses that a small amount of oil may be added atany point in the process, “but preferably just after toasting.”

Petelle et al. (U.S. Pat. No. 5,470,600) discloses a method of makingfat-free potato chips, by initially cooking potato slices in a threezone primary oven, by first radiant heating the slices and thensubjecting the slices to two successive stages of forced air heating toreduce the moisture content of the slices to near a final moisturecontent. Petelle et al. further discloses independently controlling thetime duration in each of the three zones, simultaneously forcing the airinto the top and bottom surfaces of the slices in the primary oven to anear final moisture content of about 15% by weight, independentlycontrolling the time duration of the slices in the dielectric heater toa final moisture content of about 7% by weight using wavelengths ofabout 65.8 feet at a frequency of about 15 mhz, and allowing the slicesto successively, increasingly pile up in the last two forced air stagesand the dielectric heating stage.

Benson et al. (U.S. Pat. No. 5,603,973) discloses a process for makingpotato chips without the use of oil, wherein whole potatoes are cut intodiscrete slice pieces which are washed to remove starch or debris fromthe slice surfaces. The slices are arranged in a single layer and thesurface water is removed from the slice surfaces by exposing them toblasts of air and suction. Alternatively, the slices may be washed inwarm water at a temperature of about 130° F. to preheat them. The slicesare transferred to a heated conveyor to enter an infrared zone forexposure to high intensity infrared energy for a short period of time,less than 25 seconds, effecting a blanching of the slices and quenchingof naturally-occurring deleterious enzyme action. In a subsequent step,dry air is impinged upon the slices from above and below to reduce thewater content below 35% by weight. The slices are accumulated in amulti-layer pack and dried in moving air until moisture content has beenobtained to a level on the order of 0.5% to 2%.

Wiedersatz (U.S. Pat. No. 5,858,431) discloses a method for preparingfat-free snack chips, comprising preparing slices of raw food product,which are subjected to a high intensity air knife arrangement to removesurface moisture, then exposed to a hot air fluid bed impingementincluding multiple dual-zone hot air fluid bed impingement ovensoperating under different predetermined conditions. In the preferredembodiment, the slices are exposed to two dual-zone hot air fluid bedimpingement ovens, the first oven having a conveyor belt transportingslices through the oven at a speed of 2.5 to 3.0 feet per minute andoperating at 500 to 525° F. (zone 1) and 450 to 500° F. (zone 2), andthe second oven having a conveyor belt operating at a speed of 1.5 to2.0 feet per second and at 350 to 400° F. (zone 1) and 300 to 350° F.(zone 2). The first impingement oven of the preferred embodiment removesapproximately 50 to 60 percent of the moisture in each slice, while thesecond impingement oven of the preferred embodiment removesapproximately 20 to 30 percent of the remaining moisture. The slices maythen have oil and/or seasoning applied thereto, and are passed to acombination microwave and hot air dryer which removes entrained moisturewithout scorching the chips.

Xu et al. (U.S. Patent Publication No. 2002/0004085) discloses methodsfor producing a consumable product from potatoes, comprising: (a)treating a potato substance with an effective amount of one or moreexogenous enzymes selected from the group consisting of anamyloglucosidase, glucose oxidase, laccase, lipase, maltogenic amylase,pectinase, pentosanase, protease, and transglutaminase, and (b)processing the enzyme-treated potato substance to produce a potatoproduct. In one embodiment, blanching of the potato substance may occurprior to enzyme treatment. The processing step may include partialdehydration to reduce the initial moisture content by about 5-30% priorto frying in oil or baking.

Despite the many advances in the processing of snacks and chips, therenevertheless remains a need for improvements to these products, and theprocesses for making them, characterized by improved crispness, mouthfeel and flavor properties, reduction of fat content and overallimprovement in nutritional profile, including minimization of exposureto conditions that can result in the formation of potentiallydeleterious by-products. These all require processes that are feasible,efficient, manageable, and are practically and economically scalable forproduction at output levels necessary for product commercialization inan adequately fuel efficient production environment.

SUMMARY OF THE INVENTION

A first embodiment of the present invention is directed to a method ofmaking a food product comprising,

(a) providing a plurality of cut or shaped food pieces;

(b) exposing the food pieces to a solution comprising an effectiveamount of one or more starch-reducing enzymes to coat the surfacethereof;

(c) thereafter blanching the plurality of food pieces for a timesufficient to inactivate any enzymes on the surface of the food pieces,wherein the food pieces have an initial moisture level after theblanching step; and

(d) reducing the initial moisture level to a final moisture level ofabout 0.5 to about 20% by weight, wherein the food pieces are notsubjected to cooking by immersion in hot oil (“deep fat frying”).

A second embodiment of the present invention is directed to a method ofmaking a food product comprising,

(a) providing a plurality of cut or shaped food pieces;

(b) exposing the food pieces to a solution comprising one or morecations to coat the surface thereof;

(c) thereafter blanching the plurality of food pieces for a timesufficient to inactivate any enzymes on the surface of the food pieces,wherein the food pieces have an initial moisture level after theblanching step; and

(d) reducing the initial moisture level to a final moisture level ofabout 0.5 to about 20% by weight, wherein step (d) does not comprisefrying the food pieces in hot oil.

A third embodiment of the present invention is directed to a method ofmaking a food product comprising,

(a) providing a plurality of cut or shaped food pieces;

(b) blanching the plurality of food pieces for a time sufficient toinactivate any enzymes on the surface of the food pieces, wherein thefood pieces have an initial moisture level after the blanching step; and

(c) reducing the initial moisture level to a final moisture level ofabout 0.5 to about 20% by weight by exposing the food pieces to a firstmoisture level reduction procedure which reduces the initial moisturelevel to an intermediate moisture level of about 10 to about 80% byweight, and thereafter exposing the food pieces to a second moisturelevel reduction procedure which reduces the intermediate moisture levelto the final moisture level, wherein step (c) does not comprise cookingthe food pieces in hot oil.

A fourth embodiment of the present invention is directed to a snack foodproduct comprising cut or shaped food pieces, wherein each of the foodpieces has a predetermined fat content of less than about 1 to about 35%by weight, an average force of fracture of less than or equal to 12 N,and an average Young's modulus of equal to or greater than about 3.5N/mm.

A fifth embodiment of the present invention is directed to a method ofmaking a food product comprising,

(a) providing a plurality of cut or shaped food pieces;

(b) blanching the plurality of food pieces, wherein the food pieces havean initial moisture level after the blanching step; and

(c) reducing the initial moisture level to a final moisture level ofabout 0.5 to about 20% by weight by drying the food pieces in one stepor multiple steps wherein at least one step is conducted in a rotarydryer, a fluidized bed dryer, a vibrating fluidized bed dryer and thelike or combinations thereof while controlling the temperature, air flowand movement of the food pieces to allow for even and constant exposureof the food pieces to heat, wherein step (d) does not comprise fryingthe food pieces in hot oil.

A sixth embodiment of the present invention is directed to a method ofmaking a food product comprising,

(a) providing a plurality of cut or shaped food pieces;

(b) blanching the plurality of food pieces, wherein the food pieces havean initial moisture level after the blanching step; and

(c) reducing the initial moisture level to an intermediate moisturelevel of about 10 to about 80% by weight while controlling thetemperature, air flow and movement of the food pieces to allow for evenand constant exposure of the food pieces to heat, and thereafterexposing the food pieces to a second moisture level reduction procedurewhich reduces the intermediate moisture level to the final moisturelevel, e.g., of less than 5-10 wt-% moisture. Wherein step (c) does notcomprise cooking the food pieces in hot oil.

A seventh embodiment of the present invention is directed to a method ofmaking a food product comprising,

(a) providing a plurality of cut or shaped food pieces;

(b) thereafter blanching the plurality of food pieces for a timesufficient to inactivate any enzymes on the surface of the food pieces,wherein the food pieces have an initial moisture level after theblanching step; and

(c) reducing the initial moisture level to a final moisture level ofabout 0.5 to about 20% by weight in accordance with any of theaforementioned embodiments herein, either (i) without the application ofa solution comprising enzymes and/or cations or (ii) by exposing thefood pieces to a solution comprising at least a combination of one ormore enzymes and/or one or more cations in any feasible manner,preferably in one or more aqueous solutions of the enzymes and/or thecations, that are applied before the blanching step (b) in theembodiments below to coat the surface thereof, and wherein reducing theinitial moisture level in step (c) does not comprise cooking the foodpieces in hot oil.

An eighth embodiment of the present invention provides food productssuch as snack food products made from vegetables, fruits, nuts, grainsand other consumable ingredients, and any combination thereof, and themethod of their production, where the commercial production of suchsnack foods, or the production of their healthier versions, were notpreviously feasible, or that required that the food pieces be fried inhot oil or fat.

A ninth embodiment of the present invention comprises the application tofood pieces of a mixture of water and oil, such as a homogenous mixtureof oil and water, that for convenience, will be referred to herein as awater and oil “emulsion,” although it is not necessary to employexogenous emulsifiers or surfactants to provide the beneficial effectsof the emulsion. The process can provide for the precise control of theapplication of oil to food pieces prior to the removal of moisture fromthe food pieces, for example by drying or cooking the food pieces, suchas via hot air, thermal or microwave ovens, and/or dryer(s), withoutfrying the food pieces in hot oil.

Although oil-spraying methods can be used in the present method, e.g.,to apply oil to the dried or cooked food product, the present processfor oil application can avoid the disadvantages associated with oilspraying methods in that the present method can apply a uniform coatingof oil on the surface of the food pieces. The process can further offeran advantage over the addition of oil by immersion of the food pieces in100% oil in that the process can permit a wide and preciselycontrollable range of oil content to be achieved in the finished foodproduct, anywhere from trace or low amounts of oil (about 0.2-10 wt-%)to amounts approaching those of food pieces fried in oil, while avoidingapplication of oil in the cooking/drying step(s).

The present disclosure also describes food products, such as snack foodproducts, having the texture, flavor, and other characteristics ofconventional full-fat products, but with reduced and/or controlledamounts of oil as compared to products cooked in hot oil. Acrylamidescan also be low in the present food products, e.g., potato chips andother snack food products can be prepared that have less than 150 ppbacrylamide.

In accordance with a further embodiment, a process for making a foodproduct can include:

(a) providing a plurality of cut or shaped food pieces;

(b) applying an oil-water emulsion to the food pieces for a timesufficient to provide a predetermined amount of oil to the food piecesand so that the food pieces have an initial moisture level afterapplying the oil-water emulsion; and

(c) reducing the initial moisture level to a moisture level of fromabout 0.2 to about 80% by weight, including 10-80% wt-%, such as 35-70wt-%, e.g., 40-65.

In accordance with additional embodiments, the final moisture level canbe from about 0.5 to about 5.0% by weight. Oil can be present from traceamounts, to up to about 1-3 wt-%, up to about 10 wt-%, up to about 15wt-%, or up to as high as about 30-35 wt-% oil, but in the absence of“deep fat” frying/cooking the food pieces in oil.

In accordance with a further embodiment of the invention, a method isprovided for making a food product, comprising,

(a) providing a plurality of cut or shaped food pieces;

(b) optionally exposing the food pieces to a solution comprising one ormore enzymes and/or one or more cations to coat the surface thereof;

(c) thereafter, optionally blanching the plurality of food pieces for atime sufficient to inactivate any enzymes on the surface of the foodpieces, wherein the food pieces have an initial moisture level after theblanching step;

(d) contacting the food pieces with an oil/water emulsion to impart aninitial preselected oil content to said food pieces; and

(e) reducing the initial moisture level to a moisture level of fromabout 0.2 to about 20% by weight. In accordance with additionalembodiments, the moisture level is preferably from about 0.5 to about10% by weight.

A moisture level of about 10 to about 80% by weight, preferably about 20to about 50% by weight, more preferably about 25 to about 35% by weight,may be achieved with a number of the embodiments of the presentinvention, after the first moisture level reduction step. Thereafter,the food pieces are optionally exposed to a second moisture levelreduction procedure which reduces the intermediate moisture level to thefinal moisture level. The intermediate and the final drying steps mayfurther be broken down to sub steps, or alternatively combined into onestep.

As used herein, the term “providing” the cut or shaped food piecesincludes the processor's or user's receiving pre-cut or shaped foodpieces or obtaining whole fruits and/or vegetables and then cutting,slicing or otherwise forming them into the shape of the final foodproduct, such as a chip, strip, fry, etc.

Additional features of the invention can be understood in reference tothe accompanying descriptive matter in which there is illustrated anddescribed preferred embodiments of the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

The processes described herein can provide for the preparation of foodproducts, such as snack food products, comprising a predetermined fatcontent. The process can provide for precise control of the fat contentof the food pieces. The process can include coating the food pieces witha homogenous or substantially homogenous mixture of water and oil,followed by drying the food pieces to yield a food product having thedesired oil and moisture content. More particularly, the process cancomprise applying an oil-water emulsion mixture to food pieces, such asfruit or vegetable chips or sticks, which have traditionally been friedin oil, but which can now be cooked or dried through other means in theabsence of frying, flash frying, deep fat frying or par-frying, in orderto produce a final food product possessing similar organolepticproperties to a corresponding food product fried in oil, but preferablyhaving a reduced fat content.

In examples, the oil used in the oil-water emulsion can be a natural orsynthetic edible oil. The term “edible” can refer to fats and oils thatcan be ingested by humans and animals without significant toxicity,whether or not they are nutritious. This term includes both natural andsynthetic oils. The term “fat” includes lipids that are solid at roomtemperature (20-25° C.) but are liquid at the temperaturesconventionally used to cook food pieces by frying.

A process is described herein, the process comprising:

(a) providing a plurality of cut or shaped food pieces;

(b) applying an oil-water emulsion to the food pieces for a timesufficient to provide a predetermined amount of oil to the food piecesand so that the food pieces have an initial moisture level afterapplying the oil-water emulsion; and

(c) reducing the initial moisture level to a final moisture level offrom about 0.2 wt-% to about 80 wt-% to provide a food product, in theabsence of frying in oil.

A food product is also described herein, the food product comprising aplurality of cut or shaped food pieces and a coating on the plurality offood pieces, the coating comprising an oil-water emulsion wherein theoil content of the oil-water emulsion that contacts the food pieces isfrom about 5 wt-% and about 85 wt-% of the coating. In some examples,the food pieces and the coating are dried to a moisture content of fromabout 0.2 wt-% to about 20 wt-%.

Preferably the food pieces are treated with water comprising cationsand/or effective amounts of one or more surface starch—removingor—degrading enzymes prior to blanching and application of the oil—wateremulsion. The cations can also or alternatively be included in theblanching medium, e.g., the blanch water.

In preferred embodiments, the present invention provides a snack foodproduct processed in such a manner so as to provide a plurality of cutor shaped food pieces that have a taste, texture and/or appearance ofconventionally produced products made by a process including a step inwhich the food pieces are fried in oil (typically at temperatures ofgreater than about 300° F.-400° F.) so to yield a finished food productthat contains, e.g., about 25-40 wt-% oil. Preferably, a snack foodproduct prepared in accordance with the present invention, in theabsence of frying in oil, has at least one, preferably at least three,preferably at least five, of the following attributes: a crisp texture,a fat content of less than about 35 wt-% fat, such as about 15 wt-% fator less, for example about 10 wt-% fat or less, such as about 1 wt-% fator less, for example about 0.5 wt-% fat or less; a moisture content ofgreater than about 0.1 wt-% water, such as from about 0.5 wt-% to about80 wt-%, water, or from about 0.5 wt-% to about 10 wt-% water; the foodproducts in the form of a chip, a stick, or a slice; the food piecesfracturing at less than or equal to about 12 N; and the food pieceshaving an average Young's modulus of equal to or greater than about 3.5N/mm. The food products can contain about 0.5 wt-% fat or less, up toabout 45 wt-% fat, or can comprise up to about 5-20 wt-% fat, or as muchas about 30-35 wt-% fat, e.g., about 1-15 wt-% fat. Certain of the foodpieces, such as chip-type snack food products will fracture at less thanor equal to about 12 N and have an average Young's modulus of equal toor greater than about 3.5 N/mm.

In yet another preferred embodiment the present invention provides afood product and the method of its production and/or cooking processedin such a manner so as to provide a plurality of cut or shaped foodpieces that (i) have a new and/or unique taste, texture and/orappearance, or (ii) have less fat and/or are considered as healthierversions of currently available products, or (iii) have been made fromvegetables, fruits, grains, nuts, legumes or any other consumableingredients and their combination thereof where the production of suchproducts were not previously feasible due to lack proper productionand/or cooking methods.

Surprisingly, the present invention has been found to retain the desiredhigh quality, flavor, texture, appearance and consumer acceptability ofhigh-fat snacks, through certain desirable treatment of the rawmaterials and subsequent cooking under conditions that eliminate,optionally minimize, and/or control the amount of contact with fats,such as oils or oil substitutes, and limit the potential for producingpotentially deleterious by-products such as acrylamides or carcinogenicaldehydes.

Further, in contrast with known conventional frying methods, the foodpieces can be infused with a predetermined amount of fat in a totallycontrolled environment during the production process. In addition tobeing able to control the desired amount of fat being applied to theproducts of present invention to an exact amount, the present inventionentirely eliminates the need for utilizing pools of hot oils or oilsubstitutes, and maintaining, filtering out, and, at last, in mostcases, disposing of the related fats used in the production process.

In addition, the present invention also eliminates the need for usingdefatters or other oil-removal means, such as described in the patentscited hereinabove in the production of relevant low-fat snack foodproducts.

Food Pieces

The term “food pieces” is intended to include subunits or pieces derivedfrom substantially any foods. Preferably, the food pieces may beprovided as cut or shaped food pieces that can be shaped or reshapeddirectly from their raw state. These foods include meat, poultry, fish,shellfish, vegetables and/or fruits, including potato, beet, pumpkin,squash, tomato, mushroom, zucchini, carrot, eggplant, apple, pear,bananas, berries, grains, beans, nuts, seeds, rutabaga, plantain, taro,okra, onion, parsnip, yam, sweet potato, yucca, papaya, mango,pineapple, and the like. These food pieces include pureed, sliced,diced, milled, grinded, powdered, or pulverized fruits, vegetables,legumes, grains, nuts, beans, seeds and the like, including productssuch as beans, rice, corn, wheat and the like.

Singly or in combinations, the aforementioned products and ingredients,preferably beans, rice, corn, corn masa, wheat and the like can bemanipulated to form sheets, slices or pieces of food composition throughextrusion or sheeting of a prepared dough or mixture and the like. Thedough or mixture thus formed then can be extruded or cut into anydesired shapes. There are many variations on this basic procedure formanipulating flour or dough into a shape suitable for the presentprocess. For example, see U.S. Pat. No. 3,600,193 (mixing corn flourwith seasonings); U.S. Pat. No. 3,922,370 (mixing water, rice and riceflour); and U.S. Pat. No. 3,348,950 (mixing corn, sucrose, water, andcorn grits), each of which is hereby incorporated by reference.Generally, the process of the invention can be used with all foods thatwere heretofore fried or with foods that cannot tolerate the fryingprocess. The format of the food can include, for example, sticks,strips, slices, chips, crinkle cut, waffles, popcorn texture, flakes,and the like. Flaked products may be made into bars or cerealsthemselves or used as ingredients for granola, granola bars, or add-insto yogurt, cereals, trail mixes, snack mixes, and the like.

For example, corn tortilla products, such as tortilla chips or beanchips can be prepared initially by forming a composition from water andcorn, corn masa, or bean flour, or alternatively cooked corn or beans,and cooked in conventional ovens such as tortilla ovens. Tortilla orbean strips or rounds can then be treated and processed using thecurrent invention to produce fat free or low fat snack products thathave a crispy texture and flavor of fried foods without frying in oil oroil substitutes. Generally, the process of the present invention can beused with all snack foods that have traditionally been fried in oil toachieve a crisp texture and traditional fried flavor.

In another embodiment, the sheeted or extruded dough or mixturedescribed herein can be made from a potato mixture or other starchmaterial, alone or in combination with other ingredients, and thenprocessed in accordance with the teachings of the present invention to acrispy finished product without frying.

Preferred food pieces are derived from fruits and/or vegetables thathave a generally solid inner matrix that is exposed when sliced anddemonstrates fracturability when a slice is bent. In a preferredembodiment, the food pieces are derived from potatoes such as thosegenerally used to produce potato chips. In preferred embodiments, thefood pieces comprise a potato substrate. The potato substrate may simplybe farm-grown potatoes (e.g. raw potatoes) of any variety. Suchvarieties include, but are not limited to, Bintje, Russet Burbank, YukonGold, Kennebec, Norchip, Atlantic, Shepody, Sebago, Red Pontiac, RedWarba, Irish Cobbler “BC”, Norgold Russet “BC”, Norland, Atlantic, WhiteRose, Superior, Centennial Russet, Keswick “NB 1”, Green Mountain, LaSoda, Red La Rouge, Red Nordland, Red Bliss, Yellow Finnish, RubyCrescent, and Australian Crescent, Russian Blue, Peruvian Blue,Superior, Katandin, and sweet potato varieties such as Beauregard,Jewel, Nemagold, Centennial, Excel, Regal, Southern Delite (Hernandez,Vardaman, Travis, White Delight, Sumor, Nancy Hall, Picadita, Campeon,Star Leaf/Boniato, Japanese, Chinese, and Okinawan Purple and the like.

Further processing to the food pieces can be performed as well. Forexample, for vegetable food pieces, such as potatoes to make potatochips or French fries, the process can include exposing the food piecesto a solution comprising one or more enzymes, one or more cations, orboth. The food pieces can also be blanched, such as by immersing thefood pieces in water having a temperature of from about 60° C. to about100° C., which can deactivate the enzymes. This additional processingcan be performed before applying the oil-water emulsion to the foodpieces.

In alternative embodiments, other nutrients including vitamins andminerals, such as Vitamin A, Vitamin, B6, Vitamin B12, Vitamin C,Vitamin D, Thiamin, Riboflavin, Niacin, Folic Acid, Phosphorous,Magnesium, Copper, Calcium, Zinc, Iron and the like can be added to theproducts of present invention either by infusing such vitamins andminerals into the food pieces in the enzyme treatment, cation treatment,oil application and/or blanching process, or in an additional step or byspraying a compound including any desired vitamins and/or minerals overthe food pieces prior to or after cooking. This procedure results in aproduct that is nutritionally fortified and can make snack food productsthat are healthier.

In alternate embodiments, flavor enhancers and seasoning blends such assalt (NaCl), sugar, herb extracts, fruit extracts, vegetable extractsand the like or a combination thereof can be infused into the snack foodproduct by steeping or soaking the cut food pieces with the respectivesalt, sugar, herbs, fruits, vegetables and the like, therebyincorporating these flavoring components into the food pieces either inthe blanch water and/or by having a separate step following or prior tothe blanching step in which flavors are fused into the cut food pieces.Alternately, cut food pieces may be soaked in concentrated flavorextracts that are either aqueous or otherwise. In yet anotherembodiment, the snack food products of the present invention may becoated with chocolate, caramel, syrups, and coatings made from fruits orvegetables or any other similar covering, thereby creating other novelgourmet snacks that are free of, or alternatively low or high in fat.

Food Piece Preparation.

The food pieces are cut, formed or shaped from one or a combination offood materials. For raw vegetables or raw plant materials, the foodpieces are preferably cleaned, optionally peeled, and cut. Preferredvegetables such as potatoes, vegetables, fruit, or other food productsare preferably cut into slices, sticks or strips of a desirable size andshape for chips, sticks, shoestrings, wavy cut chips, crinkle cut chips,waffle cut chips, straight cut chips and sticks and the like. Aftercutting, forming or shaping, the prepared food pieces are preferablycontacted with an aqueous medium, such as a water rinse, to remove freestarch. Removing the free starch is best for optimizing use and reducingthe amount of enzyme, plus free starch can leave a powdery appearanceafter drying the chip.

Enzyme and/or Cation Treatment:

The prepared food pieces may be exposed to an enzyme solution or acation solution, more preferably an enzyme and cation solution. Whenenzyme treatment is performed, the enzymes are preferably used inamounts that contribute to one or more of the improved properties asdefined herein and/or provide at least one of the following advantages:increasing the crispness, reducing the stickiness and improving color offinished products. Without being bound by theory, it is believed thatthe optional cations increase the activity of the enzymes, reducing timein the solution, and also make the cut food pieces more firm or rigid sothey are easier to process. Further, cations may also decrease enzymaticbrowning as well as contribute to the snack food product's nutritionalprofile.

The appropriate exposure to a given enzyme or cation for improving aspecific property or properties of a snack food product will depend onthe enzyme or cation in question. The skilled person may determine asuitable enzyme or cation exposure on the basis of methods known in theart. Where both enzyme and cation treatments are performed, thetreatments are preferably carried out simultaneously using a singlesolution, although the treatments may also be performed separately usingan enzyme solution followed by a cation solution, or a cation solutionfollowed by an enzyme solution. Salts and/or flavoring ingredients canalso be added to any of the solutions.

The enzymes to be used in the methods of the present invention may be inany form suitable for the use in question, e.g., in the form of a drypowder, agglomerated powder, or granulate, in particular a non-dustinggranulate, a liquid, in particular a stabilized liquid, or a protectedenzyme. Granulates and agglomerated powders may be prepared byconventional methods, e.g., by spraying the enzyme(s) onto a carrier ina fluid-bed granulator. The carrier may consist of particulate coreshaving a suitable particle size. The carrier may be soluble orinsoluble, e.g., a salt (such as NaCl or sodium sulfate), a sugar (suchas sucrose or lactose), a sugar alcohol (such as sorbitol), starch,rice, corn grits, or soy. The enzymes may be contained in slow-releaseformulations. Methods for preparing slow-release formulations are wellknown in the art. Liquid enzyme preparations may, for instance, bestabilized by adding nutritionally acceptable stabilizers such as asugar, a sugar alcohol or another polyol, and/or lactic acid or anotherorganic acid according to established methods.

Suitable enzymes, forms taken by the enzymes, commercial availability,etc. for use in accordance with the present invention are chosen fromone or more of the enzymes listed in U.S. Pat. Nos. 4,058,631;5,312,631; and 7,056,544, each of which is incorporated by referenceherein. Preferably, the enzyme is other than a high-temperature enzyme,such as the high temperature amylase described in U.S. Pat. No.5,441,758. However, under certain circumstances, such an enzyme may beused in accordance with the invention, and the use of a high temperatureenzyme is not disclaimed herein. Preferred enzymes in accordance withthe present invention include amylase (alpha and/or beta), cellulase,invertase, pectinase and amyloglucosidase, with amylase being the mostpreferred. Preferred enzymes are those than can degrade the starchespresent on the surfaces of the food pieces, e.g., by cleaving varioussaccharides from the starches. Such degradation may occur to starchespresent in the interior of the food pieces. Preferably, the one or moreenzymes is present in the solution at a concentration of about 0.1 toabout 5% by weight.

In accordance with the invention, the enzyme solution may furthercomprise one or more cations, or the cations can be provided in asolution without enzymes. The term “cation-producing compound” isintended to include compounds in which cations are produced in solutionvia dissociation of the cation with an anion, either at ambienttemperatures or with the addition of heat. Suitable cation-producingcompounds in accordance with the present invention include, but are notlimited to, alkali metal salts, such as lithium, sodium and/or potassiumsalts; alkaline earth metal salts, such as magnesium and/or calciumsalts; aluminum compounds; and group VA metal compounds, such asnitrogen, phosphorous and/or bismuth compounds (e.g., ammonium). Morepreferred from this set of compounds are calcium salts, magnesium salts,potassium salts, aluminum compounds and nitrogen compounds, with calciumsalts being the most preferred. Preferably, the one or more cations ispresent in the solution at a concentration of from about 0.1 to about 5%by weight, more preferably from about 0.2 to about 2.5% by weight.

The exposure of the food pieces to the enzyme solution, optionallyincluding cations as described above, or the cation solution withoutenzymes, provides various improved properties to the snack food product.The term “improved property” is defined herein as any property of asnack food product that is altered by the action of the one or moreenzymes and/or cations relative to a snack food product in which thefood pieces are not treated with such a solution. The improved propertymay include, but is not limited to, increased crispiness, reducedstickiness, increased firmness of the raw and/or blanched material,reduced browning from enzymatic and/or Maillard reactions, increasedcolor brightening, increased color retention, increased colorenhancement, reduced color fading, increased stiffness, increased ruggedor smooth appearance, improved flavor, and reduced fat content. Many ofthese terms are defined more fully in U.S. Pat. No. 7,056,544, herebyincorporated by reference. The other terms are defined in accordancewith their customary meaning as would be apparent to those of ordinaryskill in the art.

It will be appreciated that crispness and/or stiffness can be increasedin a measured or preselected way, so that, for instance, if a certaincrispness or a certain stiffness is desired to achieve certainprocessing goals or for producing a certain finished snack food product,crispness or stiffness can be controlled by varying the amount ofexposure to the one or more enzymes and/or cations.

The improved property may be determined by comparison of a snack orother food product prepared in accordance with the methods of thepresent invention, versus a snack or other food product prepared inaccordance with prior art methods. Techniques for determining suchimproved properties achieved by use of the present methods are describedherein. Organoleptic qualities may be evaluated using procedures wellestablished in the food industry, and may include, for example, the useof a trained panel of sensory evaluators. Other methods could includetexture analysis and comparisons such as those disclosed herein below.

Preferably, the food pieces are exposed to the enzyme solution (with orwithout cations), or the cation solution, for a time of about 0.5 toabout 45 minutes, more preferably about 1.0 to about 15 minutes, mostpreferably about 2.0 to about 5 minutes.

In preferred embodiments the enzyme and/or cation treatment is appliedprior to blanching. In alternative embodiments, the enzyme and/or cationtreatment is applied concurrently during the blanching, or as anadditional treatment after blanching. In the case of certain shaped foodpieces such as sheeted products that are made from a combination of foodmaterials or a dough, the enzyme and/or cation treatment may be appliedafter the shaped food pieces have been through the initial baking stepthat is customary in production of such products.

Blanching. Several embodiments of the present invention include a stepwhereby the food pieces such as fruit and/or vegetable pieces areblanched. Preferably, the food pieces are blanched for a time periodsufficient to achieve any of the following: 1) to inactivate any enzymesthat naturally occur on the surface of the pieces and/or to inactivateany enzymes added during the enzyme treatment step described above; 2)to gelatinize at least a portion of the naturally occurring starches; 3)to remove excess free sugars so as to reduce Maillard browning andpotential for formation of acrylamides; and 4) to improve texture andflavor. Typically, the food pieces are preferably blanched by immersionin an aqueous solution, preferably containing from about 0.5% to about8% by weight, more preferably from about 2% to about 5% by weight, mostpreferably about 3% by weight of one or more cations, as defined above.In preferred embodiments, the cations are selected from NaCl, KCl, MgCl₂and CaCl₂. The blanching may be conducted at a temperature of preferablyfrom about 60° C. to about 120° C., more preferably from about 70° C. toabout 100° C. In alternate embodiments, the blanching may be conductedby exposure to steam (at ambient or higher pressures). Blanching iscarried out preferably for about 15 seconds to about 10 minutes, morepreferably for about 40 seconds to about 3 minutes, depending upon theamount of blanching desired. Alternatively, any known method ofblanching such as microwave, Ohmic heating, super-heated steam, infraredheating and the like can be used in accordance with the presentinvention. Additional oil can be applied by combining it with theblanching media, e.g., water, steam and the like

If necessary, the food pieces are then preferably drained or conveyedunder an air curtain to remove excess water. In alternate embodiments,any known method of removing excess surface water may be employed. Saltcan be added before, during or after blanching. Any salts that aresuitable for use in foods may be used, but NaCl, KCl, MgCl₂, CaCl₂ andthe like are preferred.

The blanching step may not be applicable and/or necessary in cases ofcertain shaped food pieces such as sheeted products that are made from acombination of food materials or a dough. The blanching step may not benecessary for other food pieces, e.g., meat, poultry, fish or shellfish,in which blanching is not employed in the food preparation step(s).

Oils and Oil-Water Emulsion Preparation:

Any predetermined amount of digestible and/or synthetic fat, such as anoil or oil substitute, can be added to and/or blended and mixed with thedough or mixture prior to cooking or alternatively can be applied in anyprocess such as spraying the extruded dough or the food pieces, priorto, during, or after the pre-cooking steps. Preferably, at least a part,or most preferably all of the predetermined amount of oil is added tothe food pieces by immersing them in an intimate mixture of oil thatwill be referred to herein as an oil-water emulsion, prior to cookingthe food pieces, although the food pieces can be exposed to theoil-water emulsion at preselected point(s) during the cooking/dryingprocess.

Preferably, the oil is a cooking oil not containing fatty acids such ascanola, sunflower or safflower oils, which may be applied to thevegetable pieces by either, contacting the food pieces with an all-wateremulsion, spraying the oil onto the food pieces or by flash soaking thefood pieces in oil or by any other feasible method, such as applying tothe blanch water or spraying onto a conveyer belt or a tray beforeand/or after food pieces are placed onto such tray or belt. In alternateembodiments where oil is used, although any food grade oil or oilsubstitute can be used, the preferred oils will be unrefined oils andthose having a low smoke point, preferably extra virgin olive oil, hempseed oil, walnut oil, sesame oil, flaxseed oil, coconut oil, unrefinedcanola oil, semi-refined canola oil, unrefined peanut oil, saffloweroil, sunflower oil, high-oleic sunflower oil, unrefined corn oil, soyoil, unrefined soy oil, unrefined sesame oil, flavor infused oils,emulsified vegetable shortening, and the like, synthetic oils such asOLESTRA™ and the like. Alternative oils that offer health benefits, suchas SMART BALANCE™ ENOVA™ and the like, may be used either alone or incombination with other natural or synthetic oils such as those discussedabove.

As used herein the term “oil” that is part of the oil-water emulsion canrefer to liquid natural or synthetic oils that are liquid either underambient conditions, e.g., 20-25° C. (e.g., “room temperature”) or thatcan be liquefied at the temperatures employed during application of theoil-water emulsion to the food pieces. Therefore, the term “oil” canrefer to lipids that are generally referred to in the food processingindustry as “fats” because they are solid or generally solid at roomtemperature, such as butter or margarine. However, a mixture of such afat and water can be heated before forming the emulsion such that thefat melts to form a liquid that can then be emulsified with the water toform the oil-water emulsion.

The term “oil-water emulsion” or “oil-water emulsion mixture,” as usedherein, can refer to a homogenous or substantially homogenous mixture ofone or more oils and water, for example as opposed to a mixture of oiland water where the oil and water are separated into two phases with adistinct phase boundary. However, the term “oil-water emulsion” is usedherein to refer to mechanically generated dispersions of oil in water orwater in oil that are usually not true emulsions due to the absence ofnatural of synthetic surfactants. To the extent that some vegetable oranimal oils inherently contain native surface-active agents, a trueemulsion may form, but such emulsions are not essential to the practiceof the invention.

Applying the oil-water emulsion to the food pieces, can includeimmersing the food pieces in the oil-water emulsion. The conditions bywhich the immersion of the food pieces in the oil-water emulsion iscarried out can depend on several factors, including the composition ofthe oil-water emulsion and the desired final fat content of the foodpieces.

The method can also include, before step (b), a step of preparing theoil-water emulsion, for example through mechanical means of mixing oragitating an oil phase and a water phase including, but not limited to,shaking, stirring, homogenizing, exposure to ultrasound (also referredto as sonolation), agitating, or running the oil and water phasesthrough one or more mechanical pumps, such as high-shear pumps.

The oil-water emulsion can be formed by mixing together a predeterminedamount of an oil and water. As is known in the art, oils and water aregenerally immiscible due to the polar nature of water and the non-polarnature of oils such that, typically, oil and water will separate intotwo phases, an oil phase and a water phase, in the absence of addedsurfactants. Nonetheless, simple vigorous mixing and otheremulsification methods can cause one of the phases to be dispersed inthe other (e.g., the oil phase being dispersed in the water phase, orthe water phase being dispersed in the oil phase). The mixing can beperformed via any mechanical method that is capable of mixing, andpreferably, emulsifying the oil and water into an oil and wateremulsion. Examples of mixing or emulsifying methods include, but are notlimited to, homogenizing, sonolation, agitating, or running the mixturethrough one or a series of pumps, such as high-shear pumps.

The oil-water emulsion does not need to be stable, e.g., the emulsionneed not be capable of being applied in, or remaining in, a homogenousor substantially homogenous state when and/or after it is applied to thefood pieces. So long as a moisture removal step, described in moredetail below, is applied relatively soon after the oil-water emulsion isapplied, e.g., before the time it would take the oil-water emulsion toseparate back into the water phase and the oil phase, the present methodcan still be effective. Therefore, the emulsion can be preparedrelatively close in time to the application of the oil-water emulsion tothe food pieces. Moreover, because the oil-water emulsion does not needto be stable or maintained after the application period, the emulsiondoes not need to be stabilized by exogenous emulsifiers or surfactants.The oil-water emulsion can, therefore, be generated by temporarymechanical means, including but not limited to: shaking, stirring,homogenizing, exposure to ultrasound, and through the use of mechanicalpumps, including high-shear pumps. In a continuous process, the oil andwater can be heated, if necessary, and emulsified. The oil-wateremulsion can be maintained, for example by constant circulation of theoil and water through the emulsifying mechanism, and the food pieces canbe passed through the emulsion for a controlled period of time, as on amoving bed at a fixed distance below the surface of the emulsion.

The fraction of oil in the oil-water emulsion, by weight, can depend onthe desired amount of fat to be applied to the food pieces. In otherwords, the content of oil in the oil-water emulsion can be dictated by adesired final oil or fat content for the food pieces. The precise amountof oil used in the emulsion can be varied widely, e.g., from about1.5-85 wt-%, such as about 5-75 wt-% or about 10-50 wt-%, preferablyabout 20-40 wt-% oil.

As described in more detail below, the amount of oil in the oil-wateremulsion can depend on at least one, for example, at least two, at leastthree, and in some examples all four, of the following quantities: adesired final fat content of the final food product, a percentage ofmoisture in the final food product, the percentage of solids in the wetproduct, and the percentage by weight of carry-over of the oil-wateremulsion onto the surface of the food piece after application of theoil-water emulsion. The desired final fat content can be chosen by theuser. The percentage of moisture in the final product can also be chosenby the user, but can also generally be decided by the type of foodpieces, the desired type of food product, and desired physicalproperties of the final food product. For example, a high moisturecontent can be retained in the finished food product, particularly if itis derived from fish, poultry or meat, e.g., up to about 50%.

For example, for a potato chip-type food product, a final moisturecontent of about 2-10 wt-% is typical. The percentage of solids in thewet food product can depend on the type of food piece, and can bereadily determined. The carry-over of the oil-water emulsion to the foodpieces after application can be a function of the dimensions of the foodpiece (such as thickness, length, etc.), a surface texture of the foodpiece, a viscosity of the emulsion, and a temperature at which theoil-water emulsion is applied, as well as subsequent surface loss of oilin the drying process, which can be readily determined by those versedin the art.

In an example, the oil content in the oil-water emulsion can bedetermined based on a predetermined, desired final fat content for thefood pieces. It can first be assumed that the final amount of oil on thefood pieces after the step of reducing moisture will be approximatelyequal to the amount of oil that the food pieces pick up during exposureto the oil-water emulsion. Individual food pieces may lose oil or gainoil, e.g., from rubbing between the food pieces during processing, butoil lost from one food piece will most likely be picked up by anotherfood piece so that the aggregate oil loss across all the food pieceswill approximately be zero. Equation [1] shows this relationship:

m _(o) =m _(i) ×f _(co) ×f _(oe)  [1]

where m_(o) is the final mass of oil on the food pieces (e.g., afterapplying the oil-water emulsion and reducing the moisture content),m_(i) is the initial total mass of the food pieces (e.g., beforeapplying the oil-water emulsion), f_(co) is the fractional carryoverrate of oil from the oil-water emulsion onto the food piece, and f_(oe)is the fractional oil content in the oil-water emulsion.

The fractional carryover rate of oil from the oil-water emulsion f_(co),can be defined as the percentage, by weight, of carryover of theoil-water emulsion onto the surface of the food pieces. The fractionalcarryover f_(co) is generally a constant that can depend on the type offood piece (i.e., what type of food, such as potatoes, apples, poultry,fish, etc.), the shape and dimensions of the food pieces (e.g., slices,sticks, or the like, and the thickness, length, or width of the slicesor sticks), the surface texture of the food pieces, and the viscosity ofthe oil-water emulsion. In some examples, oil will be lost from the foodpieces during conveyance to the moisture-reduction step or within themoisture-reduction apparatus (e.g., during drying), but this percentageof oil loss can also be folded into the fractional carryover f_(co).

In some examples, it can be desirable to determine the oil content ofthe oil-water emulsion that should be used based on the desired finalfat content of the food pieces. Therefore, Equation [1] can be solvedfor the oil fraction of the oil-water emulsion, as shown in Equation[2].

$\begin{matrix}{f_{oe} = \frac{m_{0}}{m_{i} \times f_{co}}} & \lbrack 2\rbrack\end{matrix}$

The mass of oil on the food pieces m_(o) can be rewritten as the productof the fractional oil content on the food pieces, f_(o), and the finalmass of the food pieces, m_(fp). The mass of the food pieces m_(fp) canbe split into its three components, the mass of the solids of the foodpieces, m_(s), the final mass of water on the food pieces, m_(w), andthe mass of the oil on the food pieces m_(o). Combining theseexpressions, the mass of the oil m_(o) can be redefined by Equation [3].

m _(o) =f _(o)(m _(s) +m _(w) +m _(o))  [3]

Equation [3] can be inserted into Equation [2] to produce Equation [4].

$\begin{matrix}{f_{oe} = {\frac{f_{o}}{f_{co}} \times \frac{\left( {m_{s} + m_{w} + m_{o}} \right)}{m_{i}}}} & \lbrack 4\rbrack\end{matrix}$

The fraction m_(s)/m_(i) is the same as the initial fractional solidscontent f_(s), of the food pieces, which will generally be a known oreasily determinable property of the food pieces. Replacing this fractionwith f_(s), results in Equation [5].

$\begin{matrix}{f_{oe} = {\frac{f_{o}}{f_{co}}\left( {f_{s} + \frac{m_{o}}{m_{i}} + \frac{m_{w}}{m_{i}}} \right)}} & \lbrack 5\rbrack\end{matrix}$

Equation [5] can be manipulated slightly to result in Equation [6].

$\begin{matrix}{f_{oe} = {\frac{f_{o}}{f_{co}} \times {f_{s}\left( {1 + \frac{m_{o}}{m_{i} \times f_{s}} + \frac{m_{w}}{m_{i} \times f_{s}}} \right)}}} & \lbrack 6\rbrack\end{matrix}$

As described above, f_(s) can be defined as m_(s)/m_(i), so thatEquation [6] can be rewritten as Equations [7] and [8].

$\begin{matrix}{f_{oe} = {\frac{f_{o}}{f_{co}} \times {f_{s}\left( {1 + \frac{m_{o}}{m_{i}\left( \frac{m_{s}}{m_{i}} \right)} + \frac{m_{w}}{m_{i}\left( \frac{m_{s}}{m_{i}} \right)}} \right)}}} & \lbrack 7\rbrack \\{f_{oe} = {\frac{f_{o}}{f_{co}} \times {f_{s}\left( {1 + \frac{m_{o}}{m_{s}} + \frac{m_{w}}{m_{s}}} \right)}}} & \lbrack 8\rbrack\end{matrix}$

The fraction m_(o)/m_(s) is the same as the oil fraction in the foodpieces, defined as f_(o) above, and the fraction m_(w)/m_(s) is thewater fraction in the food pieces, which can be defined as f_(w).Substituting these fractions with f_(o) and f_(w) in Equation [8] canprovide a user-friendly Equation [9].

$\begin{matrix}{f_{oe} = {\frac{f_{o}}{f_{co}} \times {f_{s}\left( {1 + f_{o} + f_{w}} \right)}}} & \lbrack 9\rbrack\end{matrix}$

Equation [9] provides an equation that allows a user to determine thefraction of oil f_(oe) that should be used in the oil-water emulsion asa function of the following four parameters:

-   -   (1) a desired final fraction of oil on the food pieces,        designated as f_(o) in Equation [9], which is the target        parameter and can be set by the user;    -   (2) a loss-adjusted carry-over fraction, which can fold in        properties of the food piece, such as food piece geometry,        thickness, surface texture, etc., and properties of the        oil-water emulsion, such as viscosity and temperature of the        oil-water emulsion during application, designated as f_(co) in        Equation [9], which, as noted above, can be readily determined        by the user;    -   (3) the initial solids fraction of the food pieces, designated        as f_(s) in Equation [9], which can be known or readily        determined by a user; and    -   (4) the final moisture fraction f_(w), which can also be        selected by the user, but which is often set depending on the        type of food product, e.g., about 2 wt % for potato chips.

As noted above, if an oil is to be used that is solid or substantiallysolid at room temperature, the solid oil can be heated to above itsmelting point to form a heated liquid oil either before or aftercontacting the oil with the water so that the now liquid oil can beemulsified or substantially homogenously mixed with the water to formthe oil-water emulsion.

The oil-water emulsion can also include other additives, such as one ormore cations, one or more nutritional additives, one of more flavoringadditives, and one or more edible non-toxic surfactants. In an example,the oil-water emulsion can include from about 0.5 wt-% to about 8 wt-%,such as from about 2 wt-% to about 5 wt-%, for example about 3 wt-% ofone or more cations, as defined above. In some examples, the cations inthe oil-water emulsion can be selected from NaCl, KCl, MgCl₂ and CaCl₂.

Examples of nutritional additives, if included in the oil-wateremulsion, that can be used include, but are not limited to, nutrients,vitamins, and minerals, such as Vitamin A, Vitamin, B6, Vitamin B12,Vitamin C, Vitamin D, Thiamin, Riboflavin, Niacin, Folic Acid,Phosphorous, Magnesium, Copper, Calcium, Zinc, and Iron. The inclusionof nutritional additives in the oil-water emulsion can result in a foodproduct that is nutritionally fortified and provides an opportunity tomake snack food products that are healthier. In an example, theoil-water emulsion can include from about 0.25 wt-% to about 5 wt-%nutritional additives. Examples of flavoring additives, if included inthe oil-water emulsion, that can be used include, but are not limitedto, flavor enhancers and seasoning blends, such as table salt (NaCl),sugar (e.g., sucrose or fructose), herb extracts, adjuvants orflavorings, such as fruit extracts, vegetable extracts, and the like, ora combination thereof can be included in the respective flavorings,salt, sugar, herbs, fruits, vegetables, and the like, in the oil-wateremulsion, which can thereby incorporate these flavoring components intothe food pieces. Alternately, the food pieces can be soaked in orinfused with concentrated flavor extracts before applying the oil-wateremulsion, wherein the concentrated flavor extracts can be aqueous ornon-aqueous. In an example, the oil-water emulsion can include fromabout 0.25 wt-% to about 5.0 wt-% flavoring additives.

Oil-Water Emulsion Application:

The processes described herein can include one or more steps whereby anoil-water emulsion can be applied to the food pieces. In an example,application of the oil-water emulsion can be via immersion of the foodpieces in a bath of the oil-water emulsion for a predetermined period oftime and at a predetermined temperature. However, other methods ofapplying the oil-water emulsion can be used, such as spraying, pouring,painting, and the like. Immersing the food pieces in the oil-wateremulsion can be preferred because it can lead to an even application ofthe oil-water emulsion. In an example, the food pieces can be immersedin the oil-water emulsion for a time period and temperature sufficientto apply a predetermined amount of the oil-water emulsion to the foodpieces. The immersion in the oil-water emulsion can also provide for oneor more of the following additional goals, similar to blanching of foodpieces: (1) to inactivate any enzymes that naturally occur on thesurface of the pieces and/or to inactivate any enzymes added during theenzyme treatment step described above; (2) to gelatinize at least aportion of the naturally occurring starches; (3) to remove excess freesugars so as to reduce Maillard browning and potential for formation ofacrylamides; and (4) to improve texture and flavor. In an example, thetime and temperature of application in the oil-water emulsion can besufficient to achieve at least one of the additional goals listed above,for example at least two of the additional goals, such as at least threeof the additional goals, and in some examples, all four of theadditional goals can be achieved by the application of the oil-wateremulsion.

If the application of the oil-water emulsion is intended to perform ablanching function (e.g., one or more of inactivating enzymes,gelatinizing starches, removing excess free sugars, and improvingtexture and flavor), then the oil-water emulsion can be heated to atemperature and the food pieces can be immersed in the oil-wateremulsion for an amount of time that is sufficient to blanch the foodpieces and to provide for application of a predetermined amount of oilto the food pieces from the oil-water emulsion. If it is found desirableto contact the food pieces with the oil-water emulsion for a period oftime and/or temperature that is not sufficient to blanch the foodpieces, then a separate blanching step using water, oil, an oil-watermixture, steam at ambient or higher pressure, or dry blanching, can beemployed.

The emulsion application is preferably conducted at ambient temperaturesof about 20-30° F. but can be conducted over a wide temperature range,e.g., from about −20 to about 250 degrees F., e.g., about 0° C. (about32° F.) to about 100° C. (about 212° F.), such as from about 60° C.(about 140° F.) or about 65° C. (about 150° F.) to about 93° C. (about200° F.) or about 100° C. (about 212° F.), and over a wide range of timeperiods, e.g., from about 1-2 seconds to about 1-2 hours, preferablyfrom about 3 seconds to about 1 hour, e.g., from 15 seconds to about 5minutes, or from about 5 seconds to about 15 seconds. Preferably thetime and temperature are selected so a substantial amount of water isnot lost, e.g., a temperature below 100° C. (about 212° F.), preferablybelow 35° C.

The emulsion may be applied under conditions using various pressures,including atmospheric pressure under the ambient, at the ambient ofabove ambient pressure. Accordingly, the emulsion will be applied to thefood pieces and products in open chambers or in closed chambers underhigh pressure and/or under vacuum conditions.

However, the food pieces need not be partially cooked or “blanched” inthis step, and preferable will not be blanched in this step. If aseparate blanching step is needed, it may be conducted at a temperatureof from about 60° C. (about 140° F.) to about 120° C. (about 250° F.),such as from about 65° C. (about 150° F.) to about 100° C. (about 212°F.), or from about 60° C. (about 140° F.) to about 93° C. (about 200°F.) or to about 98° C. (about 210° F.). The blanching can be conductedfor about 15 seconds to about 10 minutes, such as from about 40 secondsto about 3 minutes, depending upon the amount of cooking desired.

The oil-water emulsion can be heated and circulated during theapplication step, and homogeneity can be maintained as disclosedhereinabove. The food pieces can be agitated during application andexposure to the oil-water emulsion.

In some examples, the food pieces can be rinsed, then drained orconveyed under an air curtain to remove excess emulsion. In alternateembodiments, any known method of removing excess surface liquid can beemployed. Salt can be added before, during or after application of theoil-water emulsion. Any salts that are suitable for use in foods can beused, but NaCl, KCl, MgCl₂, CaCl₂ and the like are preferred.

Reducing Moisture Level (“Cooking” or “Drying”). The moisture in thefood pieces is preferably reduced to a moisture level of about 0.2 toabout 80% by weight, preferably about 0.5 to about 5% by weight. Thismoisture reduction follows the pretreatment steps described above andmay be achieved in a number of different ways.

In one embodiment of the invention, the moisture reduction step includescooking the food pieces in one or more dryers or ovens independentlyselected from the group consisting of forced air convection ovens,fluidized bed dryers/ovens, vibrating fluidized bed dryers/ovens,impingement dryers/ovens, pulsed fluidized bed dryers/ovens (e.g., AeroPulse dryers), rotary dryers/ovens, rotary drum dryers/ovens, rotaryspiral drum dryers/ovens, tray ovens, stationary dryers/ovens, spiralroasters/dryers (such as, for example, FMC Spiral Roto-LouvreRoaster/Dryers), microwave dryers/ovens, infrared dryers/ovens, superheat airless driers, vacuum driers, vacuum belt dryers and ohmic dryers,or any similar drying/cooking apparatus that can be operated in theabsence of frying the food pieces in oil.

In one embodiment, the food pieces are cooked for about 0.5 to about 40minutes at a drier/oven(s) temperature of from about 160° F. (70° C.) toabout 400° F. (205° C.), more preferably from about 275° F. (135° C.) toabout 325° F. (165° C.) with an air velocity of about 500-1500 feet/min.

In another embodiment of the invention, the moisture reduction comprisesbringing the food pieces to a first drier/oven(s) temperature for afirst time period, and thereafter bringing the food pieces to a seconddrier/oven(s) temperature for a second time period. Preferably, bringingthe food pieces to the first drier/oven(s) temperature for the firsttime period, such as but not limited to a oven/drier(s) temperature ofabout 160° F. to about 400° F., preferably between about 300° F. toabout 400° F., e.g., about 325° F.-380° F. for a time of about 0.5 toabout 40 minutes.

This first stage reduces the initial moisture level to an intermediatemoisture level, e.g., of about 80-89 wt-% to about 10% to about 80% byweight, e.g., about 35-70 wt-% or about 40-65 wt-%. The food pieces areoptionally subsequently dried in the first or the second drier/oven(s)temperature for the second time period, such as but not limited to anoven/drier temperature of about 160° F. to about 375° F., preferablybetween about 250° F. and about 350° F., and more preferably betweenabout 260° F. to about 290° F. for a time of about 4 to about 35minutes, preferably about 5 to about 12 to about 15 minutes and morepreferably about 6 to about 11 minutes. This two stage cooking procedurereduces the intermediate moisture level to the final moisture level ofabout 0.5 to about 10%. In preferred embodiments, the second temperatureor temperature range is lower than the first temperature, or temperaturerange.

In three-stage moisture reduction steps, the third temperature ispreferably lower than the first and the second temperatures. However,the oven/drier temperatures in any stage can be varied within the rangesgiven.

The actual moisture content selected after any stage can depend on thetype of food piece being processed and the desired type of final foodproduct. For example: potato food pieces that are being prepared asFrench fries typically can have a final moisture content that is higherthan potato chips.

In other examples, the first stage of the moisture reduction process cancomprise drying the food pieces in a rotary dryer, a rotary drum dryer,a rotary spiral drum dryer, a fluidized bed dryer/oven, a vibratingfluidized bed dryer/oven, or a microwave dryer/oven, to remove up toabout 20-30% by weight, such as up to about 40% by weight, for exampleup to 50% by weight, such as up to about 60% by weight, for example upto 70% by weight, such as up to 75% by weight, for example up to 80% byweight, such as up to 85% by weight, for example up to 89% by weight,such as up to about 90% by weight of the initial moisture of the foodpieces. Thereafter, the optional second cooking stage, and optionally, athird stage, can reduce the moisture level to a desired final moisturelevel, such as from about 0.5 wt-% to about 10 wt-%, e.g., to about 2-3wt-% to about 5-7 wt-%.

In an example, the food pieces to which the oil-water emulsion isapplied can be dehydrated in a first step using a rotary dryer, a rotarydrum dryer, a rotary spiral drum dryer, or any similar apparatus at atemperature preferably ranging from about 93° C. (about 200° F.) toabout 200° C. (about 390° F.), such as from about 135° C. (about 275°F.) to about 175° C. (about 350° F.), such as from about 150° C. (about300° F.) to about 163° C. (about 325° F.) for a time interval of fromabout 2 minutes to about 20 minutes, such as from about 5 minutes toabout 15 minutes, for example from about 8 minutes to about 12 minutesprior to further cooking in an impingement oven/dryer, fluidized bedoven/dryer (including their vibratory versions), microwave oven/dryer,aero pulse oven/dryer, conviction oven/dryer, tray oven/dryer,stationary oven/dryer, continuous belt oven/dryer of any type or thelike. Alternatively, in another example, a fluidized bed oven/dryer(such as, for example, those available from The Witte Company, or theCarrier Vibrating Equipment, Inc. or the like) can be used in a processof pre-drying (dehydrating) food products in place of a rotary dryer ofany type, as described above. In yet another example, the entire dryingor dehydrating process can be achieved by using a fluidized bedoven/dryer (or a set thereof) such as those mentioned above.

In an example, the partially dehydrated cut food pieces can then betransferred to an impingement oven, a fluidized bed dryer/oven or anyother similar equipment via a conveyor belt or any other conveyingdevice or method. The partially dehydrated cut food pieces can then becooked at oven/drier temperatures of about 107° C. (about 225° F.) toabout 190° C. (about 375° F.), such as from about 135° C. (about 275°F.) up to about 177° C. (about 350° F.), for example from about 150° C.(about 300° F.) up to about 163° C. (about 325° F.) for a period of fromabout 4 minutes to about 15 minutes, such as from about 6 minutes toabout 12 minutes, for example from about 8 minutes to about 10 minutes.The resultant snack food products can then be cooled and optionallyseasoned as desired and packaged for distribution and consumption.

In still other examples, the reduction of the moisture level to thefinal moisture level of about 0.5 wt-% to about 10 wt-% can beaccomplished solely using a rotary dryer, rotary drum dryer, rotaryspiral drum dryer, fluidized bed dryer/oven or vibrating fluidized beddryer/oven, in one or more, e.g., 2 or 3, drying steps. No additionalcooking procedure need be utilized in this example. Generally the sametemperature and time conditions indicated above can be used in such anexample, over one or more stages, although it is preferred that, in atwo stage drying process that the second temperature is lower than thefirst temperature.

Another example of moisture reduction can be drying/cooking with the useof spiral roasters/dryers. The drying principles and product behaviorfor this method closely mirror rotary ovens and rotary drum drying,except the internal spiral allows for precise control of drying timewithin the vessel. Typically, in spiral roaster/dryers the drying airentry into the product bed between the spiral flights can be through aperforated plate or screen wrapped around the flights. Precise controlof drying time within the vessel combined with the use of this methodcan result in a higher product quality, process effectiveness and addedprocess efficiencies and output levels not experienced or expectedpreviously.

During any of the stages, the food pieces can be exposed to air at anair speed of from about 60 meters per minute (about 200 feet per minute)to about 4570 meters per minute (about 15,000 feet per minute).According to additional examples, even lower air velocities can be useddepending on the food pieces being prepared or the equipment being used.The process is further controlled by selectively increasing ordecreasing, or both, the air speed to control the exposure of theproduct to temperature and airflow, thereby optimizing the quality ofthe finished product. Sequential adjustments to temperature and airflowcan allow for a controlled drying process that beneficially maintainsthe product temperature below temperatures that cause browning andcarmelization until the product reaches a target moisture content.Manipulation of the different zones of temperature and air velocityallow for optimization of the texture, color, and flavor, as well aseconomical efficiency of the process.

During any of the stages, the food pieces may be exposed to air at anair speed of from about 200 to about 15,000 feet per minute. Accordingto additional, alternative embodiments of the present invention, evenlower air velocities may be used depending on the food pieces beingprepared and/or the equipment being used. The process is furthercontrolled by selectively increasing and/or decreasing the air speed tocontrol the exposure of the product to temperature and airflow, therebyoptimizing the quality of the finished product. Sequential adjustmentsto temperature and airflow allow for a controlled drying process thatbeneficially maintains the product temperature below temperatures thatcause browning and carmelization until the product reaches a targetmoisture content. Manipulation of the different zones of temperature andair velocity allow for optimization of the texture, color, and flavor,as well as economical efficiency of the process. Other equipment, suchas, for example, any similar type rotary dryer or rotary drum dryer,“flash dryers”, airless or superheated steam dryer and the like such as,for example, those available from Applied Chemical Technologies, CarrierVibrating, Inc., The Dupps Company and the like, may be used in place ofthe dryers. Alternatively, microwave, infrared, impingement, vibratingimpingement, tray oven, convection oven, stationary oven, fluidized bedor vibrating fluidized bed drying, vacuum drying, vacuum belt drying orthe like can be employed in the process of partially or completelydehydrating the cut food pieces, each resulting in a different degree ofefficiency and level of output. The use of a steam blancher, such asthose available from the Lyco Company, alone or in combination with anyof the foregoing equipment, provide numerous additional alternatives foreither a partial or complete dehydrating process. When applicable, anyversions of the foregoing equipment described herein in relation to thevarious embodiments of the present invention, such as, for instances,batch or continuous processing equipment, static or vibrating equipmentdesigns and the like may be employed.

Moisture sensing equipment such as those available from DryingTechnologies, Inc. (i.e., DTI 500, DTI 5000) and the like can beinstalled inside the rotary dryer or the like to ensure proper dryingconditions on an automated basis.

In preferred embodiments, the partially dried food pieces are thentransferred to an impingement oven, a fluidized bed dryer/oven, avibrating fluidized bed dryer/oven, a vacuum belt dryer/oven or anyother similar equipment via a conveyor belt or any other conveyingdevice or method. After moisture reduction to the final level, theresultant snack food products may then be cooled either at ambient orreduced temperatures, and optionally seasoned and/or coated as desiredand packaged for distribution and consumption.

Optional seasoning blends can be applied to products preferably usingadhesives such as gums, starches, proteins, that can be used to create asticky surface on the products for adherence of the seasoning blends asis generally known within the food industry.

The crispness of the resulting snacks food products, preferably chips orstrips, is believed to be generated by several factors including thecook-out of the starch, the resulting moisture content, the thickness ofthe resulting food portion, exposure time to enzymes, surface area percation/enzyme concentrations, drying curve, cooking time andtemperature, the variety of vegetable, potato or type of plant foodproduct used. It is believed that if vegetable pieces are dried toofast, the surfaces seal and inside moisture cannot escape, resulting inbig pockets of moisture that is believed to be undesirable. On the otherhand, if the vegetable pieces are dried too slowly, they may just gethard like dehydrated potatoes, so it is believed to be preferable tofind a middle ground in this regard.

To obtain a blistered effect on the product surface similar to thetypical appearance observed when foods are fried, the food pieces arepreferably cooked at an oven/drier temperature of at least 265° F. afterabout halfway through the moisture removal. Next, the food pieces arecooked at an oven/drier temperature of about 310° F. with a highvelocity air flow (e.g., an air speed of about 500 to about 15,000 feetper minute) to achieve a final moisture content of about 2 to about 5%.The final drying when using certain types of equipment such as a vacuumdryer may take place at temperatures below those indicated above.

The process efficiency can be further improved by, after the moisturereduction is complete, running the food pieces through an “Equilibrator”system, that takes the hot product, exhausts the air from it, pullingoff the heat thereby cooling it as the final moisture is removed.

The invention also contemplates reducing the moisture level down to theintermediate moisture level by any of the methods described herein,cooling and storing the moist product at ambient, refrigeration orfreezer conditions, then subsequently frying, drying or baking theproduct to achieve the final moisture level. Alternatively, the fryingstep may immediately follow the steps of reducing the moisture leveldown to the intermediate moisture level.

In addition, the invention contemplates flash frying or baking any ofthe snack food products prepared in accordance with the invention,either in a commercial or retail setting or at home.

The present invention also includes snack food products made by any ofthe methods described herein.

Other aspects and advantages of the present invention will be understoodupon consideration of the following illustrative and comparativeexamples.

Example 1: Potato Chips

Approximately 2,333 grams of Yukon Gold variety potatoes were washed,then sliced to an average slice thickness of 1.90 mm, yieldingapproximately 2288 grams of sliced potatoes. The sliced potatoes wererinsed for 15 seconds in cold water (18° C./65° F.) and drained. Thedrained potato slices were placed in a solution of 0.5% amylase(American Labs, Inc. Fungal Amylase-100,000 SKB/gram Lot ALI00517-04)and 1% aqueous Calcium Chloride (32% aqueous solution Calcium Chloridefrom DSM Food Specialties) and held for 3 minutes before draining. Afterdraining, the treated potato slices were blanched in 93° C. (200 degreesF.) water containing 3% salt (NaCl) (Cargill Top Flow Salt) for 1minute. Blanched potato slices were dipped into cold water for about 15seconds to halt cooking, then drained. The potato slices were thenplaced directly on a conveyor belt of an impingement oven (Impinger® I,Model No. 1240 from Lincoln Food Service Products, Inc., Fort Wayne,Ind.) set at 140° C./285° F. and belt time of 13.25 minutes. Afterdrying, the potato chips were allowed to cool completely, then placed inmoisture proof bags and sealed. The total yield was 467 grams of potatochips. The resulting chips were observed visually and determined to havea light golden color, a good potato chip flavor and a crisp lighttexture.

Samples were analyzed for moisture using the convection oven method; bymeasuring the weight lost as a result of heating a ground sample (4grams, run in triplicate) in a convection oven under controlledconditions (100° C. for 24 hours). The percent of weight lost wasreported as the percent of moisture in the sample. In this example, thefinal moisture content was 4.42%.

Samples were analyzed for fat using the chloroform extraction method ofF. I. Shahii (see reference provided below) with minor variations:

Prior to extraction, the sample is ground in a blender.

1. Prepare a 2:1 solution of chloroform: methanol.2. Measure 10 g of ground sample into a flask; add 50 mls of 2:1chloroform/methanol solution.3. Stir covered for 1 hour.4. Pour into a clean flask through filter paper.5. Rinse the initial flask and remaining solids into the new flask witha small amount of the 2:1 solution of chloroform: methanol.6. Add 30-35 mls of distilled water and mix.7. Let sit at 4° C. overnight.8. Remove settled top layer containing water and methanol with a wateraspirator and glass pipette.9. Weigh a new round bottom flask and record.10. Pour the remaining solution into the new flask through a filter,pass the remaining layer of chloroform (and fat) over sodium sulfate toremove any remaining water. Wash all of the fat into the flask usingadditional chloroform.11. Using a rotovap at 50° C./80 rpm, remove (by evaporation) theremaining chloroform.12. Place flask in the chemical fume hood overnight to completelyevaporate any remaining chloroform.13. Weigh flask after drying is complete, record and determine theamount of fat.

The results indicated that the samples contained an average of about0.30% fat. The average final thickness of the sample chips after dryingwas determined to be 1.38 mm by measuring thickness of 10 chips usingdigital calipers.

The “chloroform method” is based upon the method disclosed by F. I.Shahii, “Extraction and Measurement of Total Lipids”, Current Protocolsin Food Analytical Chemistry, John Wiley and Sons, 2003, pp D1.1.4.

The “moisture method” is based upon the method disclosed by R. P. Ruis,“Gravimetric Determination of Water by Drying and Weighing: MeasuringMoisture using a Convection Oven”, Current Protocols in Food AnalyticalChemistry, John Wiley and Sons, 2003, pp A1.1.1.

The texture of the potato chips was evaluated using a TA.XT2 TextureAnalyzer using a 0.25″ diameter ball probe and a chip/cracker fixture.Individual chips were rested over the 18 mm diameter opening on theplate's cylindrical opening, and were punctured with the ball probe. Theball probe traveled at 4.0 mm/s until a force of 10 grams was detected;then the ball probe was punctured through the chips at a speed of 1.0mm/second. The probe was withdrawn at 10.0 mm/second. A sampling of 25chips was used for each test. Analysis of the test chips resulted in anaverage peak force of 379 grams, which is statistically similar toLAY'S® Light Chips (OLESTRA™) 825.59 grams of force and Low Fat KETTLEKRISPS™ at 416.06 grams of force. LAY'S® Classic was slightly less at254.23 grams of force.

Test 1: Comparison of Chip Attributes: Samples of Potato Chips of thePresent Invention prepared by the process described in Example 1compared with popular chips currently in the market.

TABLE 1 Comparison of Chip Attributes. Average Texture Ratio of % FatPercent Percent Thickness Analysis Moisture Sample g/oz. Fat Moisture(mm) Grams of force to % Fat Test Product  0.084  0.30%* 4.42% 1.38379.87 14.73 LAYS ® Classic 10**  35.71%** 3.80% 1.44 254.23 0.11 LAYS ®Light (Contains 0**    0%** 3.45% 1.40 325.59 0 Olestra ™) LightlySalted Kettle Chips 8** 28.57%** 4.26% 1.30 583.87 0.15 Low Fat KettleKrisps   1.5** 5.36%  4.99% 1.55 416.06 0.93 Terra Yukon Gold ™ 6**21.42%** 6.27% 2.15 1090.40 0.29 *Fat analysis by Chloroform ExtractionMethod **Information from Nutritional Label

Test 2: Density measurement of potato chips using the multipycnometer.The multipycnometer (Quantachrome model MVP-D160-E) employs thetechnique of fluid displacement to determine volume. The fluid used inthe instrument is helium. Potato chip volume was determined by measuringthe pressure difference when a known quantity of helium is allowed toflow from a known reference volume into the sample cell containing thechips. Samples were weighed before measuring the volume. Each chip wasbroken into 2-4 pieces to allow them to fit into the measuring cell.Densities were calculated using the formula:

$\frac{W}{V_{C} - \left\{ {V_{R}*\left\lbrack {\left( {P_{1}/P_{2}} \right) - 1} \right\rbrack} \right\}}$

W=weight of potato chips (g)V_(C)=Cell volume (cm³)*V_(R)=Reference volume (cm³)*P₁=pressure reading of the referenceP₂=pressure reading of the cell*V_(C) and V_(R) were established during instrument calibration.

TABLE 2 Pycnometer Density Calculations of Potato Chips. SampleReplicates Density g/(cm³) Average g/(cm³) Test Product 1 1.345 1.351(regular) 2 1.359 3 1.350 Test Product 1 1.281 1.291 (wavy) 2 1.315 31.278 LAY'S ® 1 1.178 1.191 Classic 2 1.197 3 1.197 Low Fat 1 1.3731.355 Kettle Krisps 2 1.327 3 1.365 Ruffles ® 1 1.156 1.171 2 1.181 31.175

Example 2: Regular Fat-Free Potato Sticks

Russet Burbank Potatoes were peeled and cut Julienne style lengthwise toachieve approximately 2 mm height and width. After slicing 540 grams ofthese, the raw potato sticks were rinsed for under 65° F. running waterfor 15 seconds. Then the rinsed sticks were held in a solutioncontaining 500 grams water (43° C./110° F.), 5 grams bacterial amylase(Lot No. ALI05175-04, American Laboratories, Inc.), 5 grams calciumchloride solution (32% solution Calcium Chloride from DSM FoodSpecialties) for 3 minutes. The enzyme treated potato sticks weredrained, then blanched in 87° C./190° F. water containing 3% Cargill SeaSalt (3000 g cold water, plus 90 g salt) for 1 minute 30 seconds beforedraining. Blanched potato sticks were placed directly on perforatedaluminum tray and put into an impingement oven (Impinger® I, Model No.1240 from Lincoln Food Service Products, Inc., Fort Wayne, Ind.) set at140° C./285° F. Oven belt speed was set at 24 minutes. Every 5 minutes,the tray was shaken to stir the potato sticks to allow for even drying.The process yielded approximately 103 grams of fat-free potato sticks,which were then cooled and packaged. The potato sticks were evaluated bytrained sensory professionals and were noted to have a pleasant cookedpotato flavor, golden color, and light crisp texture.

Example 3: Larger Size, Puffed Potato Strips

Yukon Gold potatoes were peeled and cut slices approximately 2 mm thick.These slices were then cut into strips approximately 6 mm wide.Approximately 750 grams of these raw potato strips were rinsed under 65°F. running water for 15 seconds. Then the rinsed strips were held in asolution containing 500 grams water (43° C./110° F.), 5 grams bacterialamylase (Lot No. ALI05175-04, American Laboratories, Inc.), 5 gramscalcium chloride (32% solution Calcium Chloride from DSM FoodSpecialties) for 3 minutes. The enzyme treated potato strips weredrained, then blanched in 87° C./190° F. water containing 3% Cargill SeaSalt (3000 g water, plus 90 g salt) for 1 minute 30 seconds beforedraining. The blanched potato strips were placed directly on perforatedaluminum tray and put into an impingement oven (Impinger® I, Model No.1240 from Lincoln Food Service Products, Inc., Fort Wayne, Ind.) set at135° C./275° F. Oven belt speed was set at 27 minutes. Every 5 minutes,the tray was shaken to stir the potato strips to allow for even drying.The process yielded approximately 129 grams of fat-free potato strips,with a light texture, approximately 90% of the strips puffed into almostcylindrical shape, giving them the appearance of crispy French fries.The fat-free potato strips were judged by trained sensory professionalsto have a very rich buttery flavor, crisp light texture and appetizingappearance.

Example 4: Carrot Chips

Carrots were peeled and cut into slices approximately 2 mm thick.Approximately 500 grams of these carrot slices were rinsed under 65° F.running water for 15 seconds. Then the rinsed carrot slices were held ina solution containing 500 grams water (43° C./110° F.), 5 gramsbacterial amylase (Lot No. ALI05175-04, American Laboratories, Inc.), 5grams calcium chloride (32% solution Calcium Chloride from DSM FoodSpecialties) for 3 minutes. The enzyme treated carrot slices weredrained, then blanched in 87° C./190° F. water containing 2% Cargill SeaSalt (2000 g water, plus 40 g. salt) for 1 minute 15 seconds beforedraining. The blanched carrot slices were placed directly on belt of animpingement oven (Impinger® I, Model No. 1240 from Lincoln Food ServiceProducts, Inc., Fort Wayne, Ind.) set at 135° C./275° F. Oven belt speedwas set at 15 minutes. The process yielded approximately 120 grams offat-free carrot chips, with a light texture, bright orange color andpleasant sweet carrot flavor.

Example 5: Fat-Free Beet Chips

Fresh red beets were peeled and cut into slices approximately 1.6 mmthick. Approximately 590 grams of these beet slices were rinsed under65° F. running water for 15 seconds. Then the rinsed beet slices wereheld in a solution containing 500 grams water (43° C./110° F.), 5 gramsbacterial amylase (Lot No. ALI05175-04, American Laboratories, Inc.), 5grams calcium chloride (32% solution Calcium Chloride from DSM FoodSpecialties) for 3 minutes. The enzyme treated beet slices were drained,then blanched in 87° C./190° F. water containing 2% Cargill Sea Salt(2000 g water, plus 40 g salt) for 1 minute 15 seconds before draining.The blanched beet slices were placed directly on belt of an impingementoven (Impinger® I, Model No. 1240 from Lincoln Food Service Products,Inc., Fort Wayne, Ind.) set at 135° C./275° F. Oven belt speed was setat 15 minutes. The process yielded approximately 130 grams of fat-freebeet chips, with a light, crisp texture, dark beet red color andpleasant beet flavor.

Example 6: Fat-Free Parsnip Chips

Fresh parsnip roots were peeled and cut into slices approximately 1.6 mmthick. Approximately 500 grams of these parsnip slices were rinsed under65° F. running water for 15 seconds. Then the rinsed parsnip slices wereheld in a solution containing 500 grams water (43° C./110° F.), 5 gramsbacterial amylase (Lot No. ALI05175-04, American Laboratories, Inc.), 5grams calcium chloride (32% solution Calcium Chloride from DSM FoodSpecialties) for 3 minutes. The enzyme treated parsnip slices weredrained, then blanched in 87° C./190° F. water containing 2% Cargill SeaSalt (2000 g water, plus 40 g salt) for 1 minute 15 seconds beforedraining. Blanched parsnip slices were placed directly on belt of animpingement oven (Impinger® I, Model No. 1240 from Lincoln Food ServiceProducts, Inc., Fort Wayne, Ind.) set at 135° C./275° F. Oven belt speedwas set at 13 minutes. The process yielded approximately 120 grams offat-free parsnip chips, with a light, crisp texture, creamy tan colorand pleasant parsnip flavor.

Example 7: Fat-Free Yucca Root (Maniac or Cassava) Chips

Fresh yucca roots were peeled and cut into slices approximately 1.6 mmthick. Approximately 1000 grams of these yucca root slices were rinsedunder 65° F. running water for 15 seconds. Then the rinsed yucca rootslices were held in a solution containing 750 grams water (43° C./110°F.), 7.5 grams bacterial amylase (Lot No. ALI05175-04, AmericanLaboratories, Inc.), 7.5 grams calcium chloride (32% solution CalciumChloride from DSM Food Specialties) for 3 minutes. The enzyme treatedyucca root slices were drained, then blanched in 87° C./190° F. watercontaining 2% Cargill Sea Salt (2000 g water, plus 40 g salt) for 1minute 15 seconds before draining. Blanched yucca root slices wereplaced in apple juice for 2 minutes, then drained and placed directly onbelt of an impingement oven (Impinger® I, Model No. 1240 from LincolnFood Service Products, Inc., Fort Wayne, Ind.) set at 135° C./275° F.Oven belt speed was set at 14 minutes. The process yielded approximately200 grams of fat-free yucca root chips, with a light, crisp texture,very white in color and pleasant slightly sweet flavor.

Example 8: Fat-Free Pineapple Chips

Fresh pineapple were cored, the cored portion was then cut into slicesapproximately 1.6 mm thick. Approximately 500 grams of these pineapplecore slices were rinsed under 65° F. running water for 15 seconds. Thenthe rinsed pineapple core slices were held in a solution containing 500grams water (43° C./110° F.), 5 grams bacterial amylase (Lot No.ALI05175-04, American Laboratories, Inc.), 5 grams calcium chloride (32%solution Calcium Chloride from DSM Food Specialties) for 3 minutes. Theenzyme treated pineapple slices were drained, then blanched in 87°C./190° F. water containing 2% Cargill Sea Salt (2000 g water, plus 40 gsalt) for 1 minute 15 seconds before draining. The blanched pineappleslices were placed directly on belt of an impingement oven (Impinger® I,Model No. 1240 from Lincoln Food Service Products, Inc., Fort Wayne,Ind.) set at 140° C./285° F. Oven belt speed was set at 22 minutes. Theprocess yielded approximately 128 grams of fat-free pineapple chips,with a light, crisp texture, bright yellow color and pleasant cookedpineapple flavor

Example 9: Fat-Free Apple Chips

Fresh Fuji apples were washed then cut into slices approximately 2.0 mmthick. Approximately 900 grams of these apple slices were rinsed under65° F. running water for 15 seconds, then placed in a 1% citric acidsolution to prevent enzymatic browning. Then apple slices were held in asolution containing 500 grams water (43° C./110° F.), 5 grams bacterialamylase (Lot No. ALI05175-04, American Laboratories, Inc.), 5 gramscalcium chloride (32% solution Calcium Chloride from DSM FoodSpecialties) for 3 minutes. The enzyme treated apple slices weredrained, then blanched in 87° C./190° F. water containing 2% Cargill SeaSalt, 2% calcium chloride solution (2000 g water, plus 40 g salt and 40g calcium chloride solution) for 1 minute 15 seconds before draining.The blanched apple slices were placed directly on belt of an impingementoven (Impinger® I, Model No. 1240 from Lincoln Food Service Products,Inc., Fort Wayne, Ind.) set at 140° C./285° F. Oven belt speed was setat 14 minutes. The process yielded approximately 220 grams of fat-freeapple chips, with a light, crisp texture, light tan color and pleasantcooked apple flavor.

Example 10: Fat-Free Pear Chips

Fresh d'Anjou pears were washed then cut

into slices approximately 2.0 mm thick. Approximately 850 grams of thesepear slices were rinsed under 65° F. running water for 15 seconds, thenplaced in a 1% citric acid solution to prevent enzymatic browning. Thenpear slices were held in a solution containing 500 grams water (43°C./110° F.), 5 grams bacterial amylase (Lot No. ALI05175-04, AmericanLaboratories, Inc.), 5 grams calcium chloride (32% solution CalciumChloride from DSM Food Specialties) for 3 minutes. The enzyme treatedpear slices were drained, then blanched in 87° C./190° F. watercontaining 2% Cargill Sea Salt, 2% calcium chloride solution (2000 gwater, plus 40 g salt and 40 g calcium chloride solution) for 1 minute15 seconds before draining. The blanched pear slices were placeddirectly on belt of an impingement oven (Impinger® I, Model No. 1240from Lincoln Food Service Products, Inc., Fort Wayne, Ind.) set at 140°C./285° F. Oven belt speed was set at 15 minutes. The process yieldedapproximately 200 grams of fat-free pear chips, with a light, crisptexture, light tan color and pleasant cooked pear flavor.

Example 11: Fat-Free Purple Sweet Potato Chips

Purple Sweet Potatoes were peeled and sliced into slices approximately1.8 mm thick. After slicing, 1000 grams of these raw sweet potato sliceswere rinsed under 65° F. running water for 15 seconds. Then the rinsedslices were blanched in 87° C./190° F. water containing 2% Cargill SeaSalt (2000 g cold water, plus 40 g salt) for 1 minute 30 seconds beforedraining.

Blanched potato slices were placed directly on chain belt of impingementoven (Impinger® I, Model No. 1240 from Lincoln Food Service Products,Inc., Fort Wayne, Ind.) set at 140° C./285° F. Oven belt speed was setat 14 minutes. The process yielded approximately 225 grams of fat-freesweet potato chips, which were cooled and packaged. The purple sweetpotato slices were evaluated by trained sensory professionals and werenoted to have a very pleasant sweet flavor, novel dark purple color, andlight crisp texture.

Example 12: Fat-Free Radish Chips

Fresh red table radishes were cut into slices approximately 1.75 mmthick. Approximately 500 grams of these radish slices were rinsed under65° F. running water for 15 seconds. Then the rinsed radish slices wereheld in a solution containing 500 grams water (43° C./110° F.), 5 gramsbacterial amylase (Lot No. ALI05175-04, American Laboratories, Inc.), 5grams calcium chloride (32% solution Calcium Chloride from DSM FoodSpecialties) for 3 minutes. The enzyme treated radish slices weredrained, then blanched in 87° C./190° F. water containing 2% Cargill SeaSalt (2000 g water, plus 40 g salt) for 45 seconds before draining.Blanched radish slices were placed directly on belt of an impingementoven (Impinger® I, Model No. 1240 from Lincoln Food Service Products,Inc., Fort Wayne, Ind.) set at 135° C./275° F. Oven belt speed was setat 11.5 minutes. The process yielded approximately 109 grams of fat-freeradish chips, with a light, crisp texture, creamy tan color andastringent radish flavor.

Example 13: Fat-Free Taro Chips

Fresh taro roots were peeled and cut into slices approximately 1.6 mmthick. Approximately 1000 grams of these taro slices were rinsed under65° F. running water for 15 seconds. Then the rinsed taro slices wereheld in a solution containing 750 grams water (43° C./110° F.), 7.5grams bacterial amylase (Lot No. ALI05175-04, American Laboratories,Inc.), 5 grams calcium chloride (32% solution Calcium Chloride from DSMFood Specialties) for 3 minutes. The enzyme treated taro slices weredrained, then blanched in 87° C./190° F. water containing 2% Cargill SeaSalt (2000 g water, plus 40 g salt) for 1 minute before draining.Blanched taro slices were placed directly on belt of an impingement oven(Impinger® I, Model No. 1240 from Lincoln Food Service Products, Inc.,Fort Wayne, Ind.) set at 135° C./275° F. Oven belt speed was set at 12minutes. The process yielded approximately 255 grams of fat-free tarochips, with a light, crisp texture, creamy tan color retaining thenatural pink/red specks inherent in the taro root. Flavor was very mild,slightly sweet, and pleasant.

Example 14: Fat-Free Pumpkin Chips

A small fresh pumpkin (approximately 10 inches in diameter) was cut inquarters, seeds were removed, then the flesh was cut into slicesapproximately 1.8 mm thick. Approximately 1000 grams of these rawpumpkin slices were rinsed under 65° F. running water for 15 seconds.Then the rinsed pumpkin slices were held in a solution containing 750grams water (43° C./110° F.), 7.5 grams bacterial amylase (Lot No.ALI05175-04, American Laboratories, Inc.), 5 grams calcium chloride (32%solution Calcium Chloride from DSM Food Specialties) for 3 minutes. Theenzyme treated pumpkin slices were drained, then blanched in 87° C./190°F. water containing 2% Cargill Sea Salt (2000 g water, plus 40 g salt)for 30 seconds before draining. The blanched pumpkin slices were placeddirectly on belt of an impingement oven (Impinger® I, Model No. 1240from Lincoln Food Service Products, Inc., Fort Wayne, Ind.) set at 135°C./275° F. Oven belt speed was set at 11 minutes. The process yieldedapproximately 246 grams of fat-free pumpkin chips, with a light, crisptexture, orange/tan color and a very mild and pleasant flavor.

Example 15: Fat-Free Rutabaga Chips

Fresh rutabagas peeled and were cut into slices approximately 1.6 mmthick. Approximately 500 grams of these rutabaga slices were rinsedunder 65° F. running water for 15 seconds. Then the rinsed rutabagaslices were held in a solution containing 500 grams water (43° C./110°F.), 5 grams bacterial amylase (Lot No. ALI05175-04, AmericanLaboratories, Inc., Omaha, Nebr.), 5 grams calcium chloride (32%solution Calcium Chloride from DSM Food Specialties) for 3 minutes. Theenzyme treated rutabaga slices were drained, then blanched in 87°C./190° F. water containing 2% Cargill Sea Salt (2000 g water, plus 40 gsalt) for 1 minute 10 seconds before draining. The blanched rutabagaslices were placed directly on belt of an impingement oven (Impinger® I,Model No. 1240 from Lincoln Food Service Products, Inc., Fort Wayne,Ind.) set at 135° C./275° F. Oven belt speed was set at 12.5 minutes.The process yielded approximately 134 grams of fat-free rutabaga chips,with a light, crisp texture, bright tan color and typical cookedrutabaga flavor.

Example 16: Fat-Free Zucchini Chips

Several small fresh zucchini (approximately 2.5 inches in diameter and 8inches in length were peeled, the center core (approximately 0.5 inchdiameter) was removed, then the prepared zucchini were cut into slicesapproximately 2.0 mm thick using a kitchen mandolin with a serratedblade. Approximately 1000 grams of these raw zucchini slices were rinsedunder 65° F. running water for 15 seconds. Then the rinsed slices wereheld in a solution containing 750 grams water (43° C./110° F.), 15 gramsdried enzyme preparation (Lot No. SI9700, Multizyme II, EnzymeDevelopment Corp. New York, N.Y.), 10 grams calcium chloride (32%solution Calcium Chloride from DSM Food Specialties) for 3 minutes. Theenzyme treated zucchini slices were drained, then blanched in 87°C./190° F. water containing 2% Cargill Sea Salt (2000 g water, plus 40 gsalt) for 45 seconds before draining. The blanched zucchini slices wereplaced directly on belt of an impingement oven (Impinger® I, Model No.1240 from Lincoln Food Service Products, Inc., Fort Wayne, Ind.) set at135° C./275° F. Oven belt speed was set at 18 minutes. The processyielded approximately 96 grams of fat-free zucchini chips, with a light,crisp texture, light yellow/tan color with a very mild and pleasantflavor.

Example 17: Fat-Free Mushrooms Chips

Several small fresh button mushrooms (approximately 2.5-3 inches capdiameter) were cut into slices approximately 2.4 mm thick using akitchen mandolin. Approximately 500 grams of these raw mushroom sliceswere rinsed under 65° F. running water for 15 seconds. Then the rinsedslices were held in a solution containing 750 grams water (43° C./110°F.), 15 grams dried enzyme preparation (Lot No. S19700, Multizyme II,Enzyme Development Corp. New York, N.Y.), 10 grams calcium chloride (32%solution Calcium Chloride from DSM Food Specialties) for 3 minutes. Theenzyme treated mushroom slices were drained, then blanched in 87°C./190° F. water containing 2% Cargill Sea Salt (2000 g water, plus 40 gsalt) for 45 seconds before draining. Blanched mushroom slices wereplaced a screen sheet and placed in an impingement oven (Impinger® I,Model No. 1240 from Lincoln Food Service Products, Inc., Fort Wayne,Ind.) set at 135° C./275° F. Oven belt speed was set at 22 minutes. Theprocess yielded approximately 64 grams of fat-free mushroom chips, witha very light texture, tan color very mild and pleasant pungent cookedmushroom flavor.

Example 18: Fat Free Green Bean Sticks

Fresh green beans (Blue Lake Variety) were rinsed, the ends weretrimmed, then approximately 1000 grams of these raw green beans wererinsed under 65° F. running water for 15 seconds. Next the rinsed beanpods were held in a solution containing 750 grams water (43° C./110°F.), 15 grams dried enzyme preparation (Lot No. S19700, Multizyme II,Enzyme Development Corp. New York, N.Y.), 10 grams calcium chloride (32%solution Calcium Chloride from DSM Food Specialties) for 3 minutes. Theenzyme treated bean pods were drained, then blanched in 87° C./190° F.water containing 2% Cargill Sea Salt (2000 g water, plus 40 g salt) for4 minutes before draining. The blanched green bean pods were placed ascreen sheet on belt of an impingement oven (Impinger® I, Model No. 1240from Lincoln Food Service Products, Inc., Fort Wayne, Ind.) set at 135°C./275° F. Oven belt speed was set at 28 minutes. The process yieldedapproximately 172 grams of fat-free green bean snack sticks, with alight, crisp texture, green and brown in color with a very mild andpleasant flavor.

Example 19: Regular Fat Free Potato Chips, Pre-Processed Slices HeldUnder Refrigerated Conditions for 1 Week, then Dried/Cooked

Atlantic Variety chipping potatoes were peeled and sliced using a DitoDean vegetable slicer with a C2 blade, to achieve a slice thickness ofapproximately 1.60 mm. After slicing, 1000 grams of these raw potatoslices were rinsed for under 65° F. running water for 15 seconds. Thenthe rinsed slices were held in a solution containing 1000 grams water(43° C./110° F.), 10 grams bacterial amylase (Lot No. ALI05175-04,American Laboratories, Inc.) and 10 grams calcium chloride solution (32%solution Calcium Chloride from DSM Food Specialties) for 3 minutes. Theenzyme treated potato slices were drained, then blanched in 87° C./190°F. water containing 2% Cargill Sea Salt (3000 g cold water, plus 60 g.salt) for 1 minute before draining. The blanched potato slices werecooled in ice water, then drained and stored in plastic bags in a coolerat 3° C./38° F. for 7 days. Samples were removed from the cooler, placedin on a metal screen in a single layer and processed in an industrialAir Force® impingement oven (Heat and Control Company, Hayward, Calif.94545) set at 176° C./350° F. for 3.5 minutes. The partially driedpotato slices were then piled together to create a bed depth of 1 inch,then processed through a second Air Force® impingement oven (Heat andControl Company, Hayward, Calif. 94545) for an additional 3.5 minutes at148° C./300° F. The process yielded approximately 200 grams of fat-freepotato chips, which were cooled and packaged. The potato chips wereevaluated by trained sensory professionals and were noted to have apleasant cooked potato flavor, golden color, and light crisp texture.The seven day holding time for the pre-processed slices did not affectthe texture or flavor of the finished product.

Example 20: Novel Sweet Potato Cereal-Regular Sweet Potato Flakes

Novel Sweet Potato Cereal-Regular Sweet Potatoes were peeled and cutlengthwise into strips approximately 0.75-1 inch thick, then the stripswere sliced across into small flakes approximately 2 mm thick. Afterslicing, approximately 1000 grams of these raw sweet potato flakes wererinsed under 65° F. running water for 15 seconds. Then the rinsed flakeswere blanched in 87° C./190° F. water containing 1% Cargill Sea Salt and0.5% calcium chloride solution (32% solution Calcium Chloride from DSMFood Specialties) (5000 g cold water, plus 50 g. salt, 25 grams calciumchloride) for 1 minute before draining. The blanched sweet potato flakeswere placed directly on an aluminum screen, and put into an impingementoven (Impinger® I, Model No. 1240 from Lincoln Food Service Products,Inc., Fort Wayne, Ind.) set at 140° C./285° F. Oven belt speed was setat 17 minutes. Every 5 minutes, the screen was shaken to stir the potatoflakes to allow for even drying. The process yielded approximately 284grams of fat-free sweet potato flakes, which were cooled and packaged.The sweet potato flakes were evaluated by trained sensory professionalsand were noted to have a pleasant sweet nutty flavor, golden browncolor, and light crisp texture when eaten with milk in a bowl like agrain based cereal. The product retained its crisp texture for a bowllife of 7-8 minutes.

Example 21: Regular Fat-Free Potato Chips Made by Initial Dry withInfrared Heater, then Finish Dry in Impingement

Atlantic Variety chipping potatoes were peeled and sliced using a DitoDean vegetable slicer with a C2 blade, to achieve a slice thickness ofapproximately 1.60 mm. After slicing, 1000 grams of the raw potatoslices were rinsed for under 65° F. running water for 15 seconds. Thenthe rinsed slices were held in a solution containing 1000 grams water(43° C./110° F.), 10 grams bacterial amylase (Lot No. ALI05175-04,American Laboratories, Inc.) and 10 grams calcium chloride solution (32%solution Calcium Chloride from DSM Food Specialties) for 3 minutes. Theenzyme treated potato slices were drained, then blanched in 87° C./190°F. water containing 2% Cargill Sea Salt (3000 g cold water, plus 60 g.salt) for 1 minute before draining. The blanched potato slices wereplaced on a conveyor and run under an infra-red heater unit for 30seconds. Then the partially dried slices were immediately put into anindustrial Air Force® impingement oven (Heat and Control Company,Hayward, Calif. 94545) set at 176° C./350° F. for 3 minutes. Thepartially dried potato slices were then piled together to create a beddepth of 1 inch, then processed through a second Air Force® impingementoven (Heat and Control Company, Hayward, Calif. 94545) for an additional3 minutes at 148° C./300° F. The process yielded approximately 200 gramsof fat free potato chips, which were cooled and packaged. The potatochips were evaluated by trained sensory professionals and were noted tohave a pleasant cooked potato flavor, golden color, and light crisptexture.

Example 22: Regular Fat-Free Potato Chips Made by Initial Dry inMicrowave, then Finish Dry in Impingement Oven

Atlantic Variety chipping potatoes were peeled and sliced using a DitoDean vegetable slicer with a C2 blade, to achieve a slice thickness ofapproximately 1.60 mm. After slicing, 1000 grams of the raw potatoslices were rinsed for under 65° F. running water for 15 seconds. Thenthe rinsed slices were held in a solution containing 1000 grams water(43° C./110° F.), 10 grams bacterial amylase (Lot No. ALI05175-04,American Laboratories, Inc.) and 10 grams calcium chloride solution (32%solution Calcium Chloride from DSM Food Specialties) for 3 minutes.Enzyme treated potato slices were drained, then blanched in 87° C./190°F. water containing 2% Cargill Sea Salt (3000 g cold water, plus 60 g.salt) for 1 minute before draining. The blanched potato slices wereplaced in on plastic disc and put into a Microwave Oven (AmanaRadarRange, Model No. RS415T, 1500 Watts, manufactured by AmanaAppliances, Amana, Iowa) for 1 minute at full power. After microwavedrying the partially dried potato slices were then placed directly onthe belt in an industrial Air Force® impingement oven (Heat and ControlCompany, Hayward, Calif. 94545) set at 176° C./350° F. for 1.5 minutes.The potato slices were then piled together to create a bed depth of 1inch, then ran through a second Air Force® impingement oven (Heat andControl Company, Hayward, Calif. 94545) for an additional 1.5 minutesbut at 148° C./300° F. The process yielded approximately 200 grams offat-free potato chips, which were cooled and packaged. The potato chipswere evaluated by trained sensory professionals and were noted to have apleasant cooked potato flavor, golden color, and light crisp texture.

Example 23: Larger Size, Puffed Potato Strips Made by Steam BlanchInstead of Immersion Blanch, Lincoln Impingement Finish

Yukon Gold potatoes were peeled and cut slices approximately 2 mm thick.These slices were then cut into strips approximately 6 mm wide, 6 cm inlength. Approximately 750 grams of the raw potato strips were rinsedunder 65° F. running water for 15 seconds. Then the rinsed strips wereheld in a solution containing 500 grams water (43° C./110° F.), 5 gramsbacterial amylase (Lot No. ALI05175-04, American Laboratories, Inc.), 5grams calcium chloride (32% solution Calcium Chloride from DSM FoodSpecialties) for 3 minutes. The enzyme treated potato strips weredrained, then blanched using steam in a M-6 Dixie VegetableBlancher/Cooler (Dixie Canning Company, Athens Ga., 30603) for 30seconds. The hot steam blanched potato strips were placed directly onperforated aluminum tray and put into an impingement oven (Impinger® I,Model No. 1240 from Lincoln Food Service Products, Inc., Fort Wayne,Ind.) set at 135° C./275° F. Oven belt speed was set at 27 minutes.Every 5 minutes, the tray was shaken to stir the potato strips to allowfor even drying. The process yielded approximately 129 grams of fat-freepotato strips, with a light texture, approximately 90% of the stripspuffed into almost cylindrical shape, giving them the appearance ofcrispy French fries. The fat-free potato strips were judged by trainedsensory professionals to have a very rich buttery flavor, crisp lighttexture and appetizing appearance.

Example 24: Impingement Oven for Initial Dry, then Pulsing Fluid BedDryer for Final Regular Fat Free Potato Chips

Atlantic Variety chipping potatoes were peeled and sliced using a DitoDean vegetable slicer with a C2 blade, to achieve slice thicknesses ofapproximately 1.60 mm. After slicing, 1000 grams of the raw potatoslices were rinsed for under 65° F. running water for 15 seconds. Thenthe rinsed slices were held in a solution containing 1000 grams water(43° C./110° F.), 10 grams bacterial amylase (Lot No. ALI05175-04,American Laboratories, Inc.), 10 grams calcium chloride solution (32%solution Calcium Chloride from DSM Food Specialties) for 3 minutes. Theenzyme treated potato slices were drained, then blanched in 87° C./190°F. water containing 2% Cargill Sea Salt (3000 g cold water, plus 60 g.salt) for 1 minute before draining. The blanched potato slices wereplaced directly on the belt of and impingement oven set at 176° C./350°F., and dried for 1 minute to reduce the moisture content to 50%, thenthe chips were layered to a bed depth of 3 inches, then placed into anindustrial Aeropulse® pulsed-air fluid bed processor (AeroglideCorporation, Raleigh, N.C. 27626) set at 148° C./300° F. for 5 minutes.The process yielded approximately 200 grams of fat free potato chips,which were cooled and packaged. The potato chips were evaluated bytrained sensory professionals and were noted to have a pleasant cookedpotato flavor, golden color, and light crisp texture.

Example 25: Wavy or Ripple Fat-Free Potato Chips

Atlantic variety potatoes were peeled and sliced on a mandolincorrugated blade so that slices approximately 2 mm height at thethickest point and 1.65 mm at the thinnest point were formed verysimilar in appearance, shape and thickness to potato chips marketedcurrently under the names of “wavy” or “Ripple” chips. After slicing,500 grams of these the raw potato slices were rinsed for under 65° F.running water for 15 seconds. Then the rinsed slices were held in asolution containing 500 grams water (43° C./110° F.), 5 grams bacterialamylase (Lot No. ALI05175-04, American Laboratories, Inc.), 5 gramscalcium chloride solution (32% solution Calcium Chloride from DSM FoodSpecialties) for three minutes. The enzyme treated potato slices weredrained, then blanched using steam in a M-6 Dixie VegetableBlancher/Cooler (Dixie Canning Company, Athens Ga., 30603) by exposingthe slices directly to steam for 30 seconds at atmospheric conditions.Blanched potato slices were placed directly on and put into animpingement oven (Impinger® I, Model No. 1240 from Lincoln Food ServiceProducts, Inc., Fort Wayne, Ind.) set at 140° C./285° F. Oven belt speedwas set at 24 minutes. The process yielded approximately 110 grams offat-free potato chips, which were then cooled and packaged. The potatochips were evaluated by trained sensory professionals and were noted tohave a pleasant cooked potato flavor, golden color, and light crisptexture.

Example 26: Puffy Potato Chips

Yukon Gold potatoes were peeled and cut into slices approximately 2 mmthick. Approximately 750 grams of these raw potato strips were rinsedunder 65° F. running water for 15 seconds. Then the rinsed slices wereheld in a solution containing 500 grams water (43° C./110° F.), 5 gramsbacterial amylase (Lot No. ALI05175-04, American Laboratories, Inc.), 5grams calcium chloride (32% solution Calcium Chloride from DSM FoodSpecialties) for 3 minutes. The enzyme treated potato slices weredrained, then blanched in 87° C./190° F. water containing 2.5% CargillSea Salt (3000 g water, plus 75 g salt) for 1 minute 30 seconds beforedraining. Blanched potato slices were placed directly on a wire belt andran through an impingement oven (Impinger® I, Model No. 1240 fromLincoln Food Service Products, Inc., Fort Wayne, Ind.) set at 140°C./285° F. Oven belt speed was set at 9 minutes for the initial pass,then the potato slices were ran through again for 6 minutes. The processyielded approximately 135 grams of fat-free potato chips, with a lighttexture, approximately 90% of the chips puffed into a thicker shape witha pillow-like appearance and hollow center. These puffy, fat-free potatochips were judged by trained sensory professionals to have a very richbuttery flavor, crisp light texture, and appetizing appearance.

Example 27: Fat-Free Sweet Potato Chips

Organic Japanese Sweet Potatoes were peeled and sliced into slicesapproximately 1.8 mm thick. After slicing, 1000 grams of these raw sweetpotato slices were rinsed under 65° F. running water for 15 seconds.Then the rinsed slices were blanched in 87° C./190° F. water containing2% Cargill Sea Salt (2000 g cold water, plus 40 g salt) for 1 minute 30seconds before draining. Blanched slices were placed directly on chainbelt of impingement oven (Impinger® I, Model No. 1240 from Lincoln FoodService Products, Inc., Fort Wayne, Ind.) set at 140° C./285° F. Ovenbelt speed was set at 14 minutes. The process yielded approximately 230grams of fat-free sweet potato chips, which were cooled and packaged.The sweet potato chips were evaluated by trained sensory professionalsand were noted to have a very pleasant sweet flavor, bright orangecolor, and light crisp texture.

Example 28: Use of Rotary or Rotary Drum Dryer as the First Step of theCooking Process

Chipping potatoes were washed, peeled, sliced to approximately 1.55 mmthickness, and then washed and exposed to a solution containingbacterial amylase (Lot No. AL105175-04, American Laboratories, Inc.),and calcium chloride solution (32% solution Calcium Chloride from DSMFood Specialties). Next the enzyme treated potato slices were drainedfollowed by blanching at 87° C./190° F. water containing 2% Cargill seasalt before then again draining. Then the blanched potato slices werecooled and stored. Several samples of the sliced potatoes were tested onan Omni Mark moisture analyzer available from Denver Equipment Companybefore and after the dehydrating step. The analyzer indicated that rawenzyme treated potato slices had a moisture level between 80% and 85%after blanching and just prior to drying.

The sliced potatoes were then placed in bulk form inside a rotary drumdryer provided by Spray Dynamics and partially dehydrated in massquantity at a temperature of about 300° F. for about 10 minutes. Thepartially dehydrated slices were then removed from the rotary dryer andvisually tested for quality, color, texture, breakage, smell and flavor.Surprisingly, all slices had an excellent texture, color, flavor, smell,and, even, more surprisingly minimal, if any, breakage, sticking or anyother visual impairment was noticed. The drying was uniform and allslices had similar color and a consistent level of dehydration.

The test was repeated for several times at temperatures ranging betweenabout 275° F. and about 350° F. and for periods as low as about 5 and ashigh as about 14 minutes. The visual results were all surprisingly goodas in the first trail and consistent among trials.

Moisture levels following the dehydrating processes of various lengthsbetween about 5 to about 14 minutes produced snack food slices with amoisture content ranging between about 40% and about 70%.

To further test the efficacy of the teachings of the present inventionan additional test was conducted using the rotary drum dryer availablefrom Spray Dynamics. Potato slices without enzyme treatment were placedin the drum dryer in the same manner as explained above and partiallydehydrated at 300° F. for periods as high as about 12 minutes. Theprocess consistently produced less preferable results as, following thedehydrating step, the slices had a color, texture, quality, flavor andodor deemed to be commercially undesirable. The drying was inconsistent.Some slices had dried out to a hard consistency similar to and/or as ofdehydrated potatoes. Other slices, however, were totally or partiallywet or even burnt totally or around the edges. It is believed that foodproducts containing high levels of starch will be greatly enhanced byusing an enzyme treatment as the enzyme treatment possibly breaks downthe sugars on the surface of the food slice.

Then, the pretreated dehydrated potato slices of potatoes processed inaccordance with the teachings of the present invention were used toproduce potato chips that have same texture, crunchiness, color, tasteand mouth feel as conventionally deep fried potato chips. Pretreatedpotato slices cooked at a temperature of about 300° F. for about 8minutes containing approximately 51% moisture (Pretreated DehydratedPotato Slices) were used in the following tests.

Example 28A

Approximately 5,000 grams of the Pretreated Dehydrated Potato Sliceswere poured onto the opening conveyer belt of a fluidized bed dryeravailable from Witte Company and were further massively subjected toheat at a temperature of about 325° F. for about 6 minutes. The airvelocity was between about 300 to about 350 cfm. The cooked PretreatedDehydrated Potato Slices were then left to cool down to ambienttemperature (80° F.). The resulting potato chips, included some airpockets/blistering resembling conventional fried chips, and hadexcellent texture, mouth feel, taste, color, and crunchiness totallycommensurate with or better than that of their counterpart potato chipsthat are made through conventionally deep frying methods. The trialyielded approximately 1,990 grams of fat free potato chips.

Example 28B

Approximately 1,500 grams of the Pretreated Dehydrated Potato Sliceswere placed in a multiple layer configuration on the conveyer belt of anindustrial Air Force® impingement oven (Heat and Control Company,Hayward, Calif. 94545) creating a bed depth of 1 inch, then processedfor 5.5 minutes at 148° C./300° F. The process yielded approximately 660grams of fat-free potato chips, which were cooled and packaged. Thepotato chips were evaluated by trained sensory professionals and werenoted to have a pleasant cooked potato flavor, golden color, and lightcrisp texture.

Example 28C

Approximately 2,000 grams of the Pretreated Dehydrated Potato Sliceswere processed further in a multi-layer format using an industrialAeropulse® pulsed-air fluid bed processor (Aeroglide Corporation,Raleigh, N.C. 27626) set at 148° C./300° F. for 5 minutes. The processyielded approximately 830 grams of fat free potato chips, which werecooled and packaged. The potato chips were evaluated by trained sensoryprofessionals and were noted to have a pleasant cooked potato flavor,golden color, and light crisp texture.

Example 28D

Approximately 1000 grams of the Pretreated Dehydrated Potato Slices werefurther processed using a convection oven (Model #6203, Lincoln Steam'rOven, Lincoln Food Service Products, Fort Wayne, Ind.). The potatoslices were placed on perforated trays and cooked in the oven for 12minutes at 148° C./300° F. until the products were fully dried. Thetrial resulted in approximately 400 grams of finished fat free potatochips. The potato chips were evaluated by trained sensory professionalsand were noted to have a pleasant cooked potato flavor, golden color,and light crisp texture.

Example 28E

Approximately 2000 grams of the Pretreated Dehydrated Potato Slices werefurther processed in a stationary tray dryer (National Dryer MachineryCompany, Philadelphia, Pa.), by placing the potato slices in a layerapproximately ¾ inch deep and drying for 16 minutes at a temperature of148° C./300° F. The trial resulted in approximately 810 grams of fatfree potato chips. These chips were evaluated by trained sensoryprofessionals and were noted to have a bright golden color, excellentpotato chip flavor and light crisp texture.

Example 29

Impingement oven for initial dry, then vibrating fluidized bed dryer forfinal Regular Fat Free Potato Chips: Snowden variety chipping potatoeswere washed and sliced using a Ditto Dean vegetable slicer with a C3blade, to achieve slice thicknesses of approximately 1.60 mm. Afterslicing, 3.95 lbs. of the raw potato slices were rinsed for under 65° F.running water for 15 seconds. Then the rinsed slices were held in asolution containing 3000 grams water (43° C./110° F.), 30 gramsbacterial amylase (Lot No. ALI05175-04, American Laboratories, Inc.), 30grams calcium chloride solution (32% solution Calcium Chloride from DSMFood Specialties) for 3 minutes. The enzyme treated potato slices weredrained, then blanched using steam in a M-6 Dixie VegetableBlancher/Cooler (Dixie Canning Company, Athens Ga., 30603) for 40seconds. The blanched potato slices were placed directly on the belt ofand impingement oven set at 176° C./350° F., and dried for 5 minutes toreduce the moisture content to 36%, then the chips were layered to a beddepth of 2 inches, then placed into an lab model vibrating fluid bedprocessor (Carrier Vibrating Equipment, Inc., Louisville, Ky. 40213)with a drilled hole type plate, and dried/cooked at 160° C./320° F. for2 minutes. The process yielded approximately 1 pound of fat free potatochips, which were cooled and packaged. The potato chips were evaluatedby trained sensory professionals and were noted to have a pleasantcooked potato flavor, golden color, and light crisp texture.

Example 30

Steam Blanch, then vibrating fluidized bed dryer for entire drying stepon Fat Free Sweet Potato Chips: Common variety sweet potatoes werewashed, peeled, and sliced using a Ditto Dean vegetable slicer with a C3blade, to achieve slice thicknesses of approximately 1.80 mm. Afterslicing, 3.0 lbs. of the raw sweet potato slices were rinsed for under65° F. running water for 15 seconds. Then the rinsed slices were drainedand blanched using steam in a M-6 Dixie Vegetable Blancher/Cooler (DixieCanning Company, Athens Ga., 30603) for 50 seconds. The blanched sweetpotato slices were rinsed under cold water spray for 3 minutes, drainedthen stored in plastic bags in a cooler overnight. The blanched sweetpotato slices were layered to a bed depth of 2 inches in an lab modelvibrating fluid bed processor (Carrier Vibrating Equipment, Inc.,Louisville, Ky. 40213) with a drilled hole type plate, and dried/cookedat 176° C./350° F. for 4 minutes. Temperature of the processor was thenreduced to 160° C./320° F. and product was cooked for an additional 2minutes before the processor temperature was reduced to 148° C./300° F.for additional two minutes of final drying/cooking time. The sequentialtemperature reductions allowed for a controlled drying process,maintaining product temperature below 148° C./300° F. at the finalstages of drying when no evaporative cooling was taking place to preventproduct browning and controlling caramelization of natural sugarspresent in the product. This controlled process yielded approximately0.75 of fat-free sweet potato chips, which were cooled and packaged. Thesweet potato chips were evaluated by trained sensory professionals andwere noted to have a very pleasant sweet flavor, bright orange color,and light crisp texture.

The above process was repeated a number of times with sweet potatoesthat were additionally treated with calcium chloride, amylase enzyme andthe combination of the two yielding desired products with great color,texture and taste.

Additionally, pears, apples, squash, and a varieties of carrotsincluding yellow, orange, white and purple carrots were processed insimilar procedures as above all resulting in excellent products havinggreat taste, color and texture.

Example 31

Steam Blanch, then vibrating fluidized bed dryer for entire drying stepon Fat Free Potato Sticks: Common Russet potatoes were washed, peeled,and sliced using a Ditto Dean vegetable slicer with an AS-4 blade, toachieve julienne slice or stick shape with 2.0 mm square, and averagelength of 8 cm. After slicing, 2.80 lbs. of the raw potato sticks wererinsed for under 65° F. running water for 15 seconds. Then the rinsedpotato sticks were drained, held in a solution containing 3000 gramswater (43° C./110° F.), 30 grams bacterial amylase (Lot No. ALI05175-04,American Laboratories, Inc.), 30 grams calcium chloride solution (32%solution Calcium Chloride from DSM Food Specialties) for 3 minutes. Theenzyme treated potato sticks were drained, and blanched using steam in aM-6 Dixie Vegetable Blancher/Cooler (Dixie Canning Company, Athens Ga.,30603) for 55 seconds. The blanched potato sticks were rinsed under coldwater spray for 3 minutes, drained, then potato sticks were marinated ina in a solution containing 1000 g. water, 75 grams of tomato juice, 10grams lemon juice, 10 grams carrot juice plus 10 grams of salt in acooler overnight. The following day, the marinated potato sticks weredrained and layered to a bed depth of 2 inches in an lab model vibratingfluid bed processor (Carrier Vibrating Equipment, Inc., Louisville, Ky.40213) with a drilled hole type plate, and dried/cooked at 160° C./320°F. for 6 minutes. Temperature of the processor was then reduced to 148°C./300° F. and product was cooked for an additional 2 minutes before theprocessor temperature was reduced to 140° C./285° F. for additional twominutes of final drying time. The sequential temperature reductionsallowed for a controlled drying process, maintaining product temperaturebelow 148° C./300° F. at the final stages of drying when no evaporativecooling was taking place to prevent product browning and controllingcaramelization of natural sugars present in the product. This controlledprocess yielded approximately 0.60 of fat-free potato sticks, which werecooled and packaged. The resulting product was very bright golden incolor, with a pleasant, slightly salty buttery potato flavor and havingan excellent crispy light texture.

Example 32

Fat-Free Tortilla Chips using vibrating fluidized bed dryer for finalcooking: Commercial 6 inch diameter white corn tortillas were purchasedat the local grocery store, each tortilla was cut into eight wedges ortriangles. Approximately 500 grams of these tortilla pieces were held ina solution containing 3000 grams water (43° C./110° F.), 30 gramsbacterial amylase (Lot No. ALI05175-04, American Laboratories, Inc.), 30grams calcium chloride solution (32% solution Calcium Chloride from DSMFood Specialties) for 3 minutes. The enzyme treated tortilla pieces weredrained, then layered to a bed depth of 1½ inches and placed into a labmodel vibrating fluid bed processor (Carrier Vibrating Equipment, Inc.,Louisville, Ky. 40213) with a drilled hole type plate, and dried/cookedat 160° C./320° F. for 7 minutes. The process yielded approximately 200grams of tortilla chips, which were cooled and packaged. The tortillachips were evaluated by trained sensory professionals and were noted tohave a pleasant cooked tortilla flavor, a very light golden color,smooth appearance, and light crisp texture. When compared with a sampleprocessed in a similar manner but without the enzyme treatment, thesample processed using the procedure of the present invention was notedto be much lighter in texture and exhibited a lighter crunch andcrispiness. The sample processed without enzyme treatment but ratherheld in just water for 3 minutes was tough and less crispy than the onewhich was produced using the process of the present invention.

Example 33. Application of Oil Via Oil-Water Emulsion

Potatoes were washed and sliced to an average slice thickness of 1.95mm. The sliced potatoes were washed with water and then placed in anamylase enzyme solution formed by adding 4945 grams (about 10.9 lbs) ofamylase (Specialty Enzymes & Biotechnologies Co., SEBamyl L LiquidBeta-Amylase) and 3265 grams (about 7.2 lbs) of calcium chloride(Nelson-Jameson, Inc., Food-Grade 32% Calcium Chloride) to 397 liters(about 105 gallons) of warm water (41.1° C., about 106° F.). The potatoslices were immersed in the amylase enzyme solution for about 3 minutesbefore draining. After draining, the enzyme-treated potato slices wereblanched in 87.8° C. (about 190° F.) water for 90 seconds. The blanchedpotato slices were dipped into cold water for about 15 seconds to haltcooking, then drained.

An oil-water emulsion was formed by adding 3.8 liters (about 1 gallon)of corn oil to 185 liters (about 49 gallons) of water. A circulationpump emulsified the oil and water mixture to a cloudy, even,bluish-white texture to form an oil-water emulsion. Tests of theoil-water emulsion via volumetric weighing showed an oil content at thesurface of about 28% by weight. The enzyme-treated and blanched potatoslices were immersed in the oil-water emulsion mixture for a period ofabout 5 seconds to about 10 seconds at a depth of about one inch on amoving belt. The oil-treated slices were dried and cooked as follows:Dryer stage 1 (batch mode): Food pieces were dried at 380° F. for 7minutes, and then at 360° F. for another 7 minutes in a vibratingfluidized bed dryer, for a total of 14 minutes in stage 1. The bed isdrilled with 3/16″ diameter holes spaced 1″ apart. Vibration angle is 3degrees backwards from vertical. Process air (a measure of how much airis flowing through the dryer) measures a 3″ pressure drop. Pressure inthe plenum (a measure of air velocity through the holes) is 9.75″.

Dryer stage 2 (batch mode): Food pieces were dried at 260-290° F. for 13minutes in a vibrating fluidized bed dryer. The bed is drilled with ⅛″diameter holes paced 1″ apart. Vibration angle is vertical. Process air(a measure of how much air is flowing through the dryer) measures a 0.5″pressure drop. Pressure in the plenum is 4.5-5″.

The fractional carryover rate of the oil-water emulsion to the potatoslices was measured as about 7% and the potato solids fraction wasdetermined to be 21%. Using Equation [9], described above, the predictedfinal oil content of the potato slices (chips) was about 9 wt % oil,which was confirmed by laboratory analysis. The final moisture contentwas about 3 wt-%.

Example 34. Oil Application Via Oil-Water Emulsion

Potatoes are washed and sliced to an average slice thickness of 1.7 mm.The sliced potatoes are washed with water and then placed in an amylaseenzyme solution formed by adding 4945 grams (about 10.9 lbs) of amylase(Specialty Enzymes & Biotechnologies Co., SEBamyl L Liquid Beta-Amylase)and 3265 grams (about 7.2 lbs) of calcium chloride (Nelson-Jameson,Inc., Food-Grade 32% Calcium Chloride) to 397 liters (about 105 gallons)of warm water (41.1° C., about 106° F.). The potato slices are immersedin the amylase enzyme solution for about 3 minutes before draining.After draining, the enzyme-treated potato slices are blanched in 87.8°C. (about 190° F.) water for 90 seconds. The blanched potato slices aredipped into cold water for about 15 seconds to halt cooking, thendrained.

An oil-water emulsion is formed by adding 40 liters of sunflower oil to160 liters of water. A homogenizer produced an even oil-water emulsionmixture that was 25% oil by volume. The enzyme-treated and blanchedpotato slices of thickness of 1.7 mm are immersed in the 25% oilemulsion for a period of about 5 seconds to about 10 seconds.

Dryer stage 1 (batch mode): Food pieces are dried at 380° F. for 7minutes, and then at 360° F. for another 7 minutes in a vibratingfluidized bed dryer, for a total of 14 minutes in stage 1. The bed isdrilled with 3/16″ diameter holes spaced 1″ apart. Vibration angle is 3degrees backwards from vertical. Process air (a measure of how much airis flowing through the dryer) measures a 3″ pressure drop. Pressure inthe plenum (a measure of air velocity through the holes) is 9.75″.

Dryer stage 2 (batch mode): Food pieces are dried at 260-290° F. for 13minutes in a vibrating fluidized bed dryer. The bed is drilled with ⅛″diameter holes paced 1″ apart. Vibration angle is vertical. Process air(a measure of how much air is flowing through the dryer) measures a 0.5″pressure drop. Pressure in the plenum is 4.5-5″.

The fractional carryover rate of the sunflower oil-water emulsion to thepotato slices is measured as 9% and the potato solids fraction isdetermined to be 19%. The final oil content of the potato slices (chips)is determined to be about 12 wt-% oil. The final moisture content isabout 1-3 wt-%.

Example 35 Sweet Potato Chips Using Oil-in-Water Emulsion

Sweet potatoes are washed and sliced to an average slice thickness of 2mm. The slices were placed in a solution formed by adding 12 lbs of seasalt (1.4 wt-%) and 1.3 lbs (0.15 wt-%) of calcium chloride(Nelson-Jameson, Inc., Food-Grade 32% Calcium Chloride) to 397 liters(about 105 gallons) of warm water (41.1° C., about 106° F.). The sweetpotato slices are immersed in the salt solution for about 5 minutesbefore draining. After draining, the enzyme-treated potato slices areblanched in 85° C. (about 185° F.) water for 90 seconds. The blanchedpotato slices are dipped into cold water for about 15 seconds to haltcooking, then drained.

An oil-water emulsion is formed by adding 1 gal of corn oil to 55 litersof water. A homogenizer produced an oil-water emulsion mixture that was35% oil by volume at the surface. The blanched potato slices wereimmersed in the emulsion mixture just below the surface for a period of5 to 10 seconds at room temperature.

Dryer stage 1 (batch mode): Potato slices were dried at 345° F. for 7minutes in a vibrating fluidized bed drier, he bed is drilled with 3/16″diameter holes spaced 1″ apart. Vibration angle was 3 degrees backwardsfrom vertical. Process air (a measure of how much air is flowing throughthe dryer) measured a 2.5″ pressure drop. Pressure in the plenum (ameasure of air velocity through the holes) was 7.55″.

Dryer stage 2 (batch mode): Potato slices were dried at 250° F. for 7minutes in a vibrating fluidized bed dryer. The bed is drilled with ⅛″diameter holes paced 1″ apart. Vibration angle is vertical. Process air(a measure of how much air is flowing through the dryer) measured a 1.2″pressure drop. Pressure in the plenum is 4.5-5″.

The fractional carryover rate of the oil-water emulsion to the sweetpotato slices (chips) is measured as 6.5% and the potato solids fractionis determined to be 23%. The final oil content of the sweet potatoslices was calculated to be about 10 wt % oil. The final moisturecontent was about 3 wt-%.

Example 37: Crispness Tests

Vegetable snack chips are favored for their crispy, crunchy bite whichis particularly characteristic of traditional fried chips. Crispness andcrunchiness can be quantified with an instrument that records the forcerequired to break chips as well as their stiffness prior to failure. Theratio of increased resistance to increased flexure or deformation isYoung's modulus (also called the elastic modulus). Vickers andChristensen (Vickers, Z. M. and Christensen, C. M. 1980. Relationshipbetween sensory crispness and other sensory and instrumental parameters.Journal of Texture Studies 11: 291-307) found that, of instrumentalmeasurements, Young's modulus had the highest correlation to crispnessin foods. These authors showed that it is also helpful to record thesound made when the chip breaks since they found crispness was veryclosely related to loudness during fracture. The importance of snackfood sound is underscored by Vickers' (Vickers, Z. M. 1983. Pleasantnessof Food Sounds. Journal of Food Science 48: 783-786) observation thatpleasantness of food sounds was highly correlated with descriptors‘crisp’ and ‘crunchy.’

Accordingly, to be perceived as crisp and crunchy, snack food productsneed to have an adequate stiffness, (as reflected in Young's modulus)and to emit at least a certain level of sound upon breaking. At the sametime, snack food products should not require so great a force as tocause mouth pain or injury. To evaluate crispness, samples werefractured on a TA.XT Plus Texture Analyzer (Stable Microsystems,Godalming, U.K.) fitted with a TA-101 Chip Rig and a 5 kg load cell. TheTA-101 rig has 2 cm diameter by 2 cm tall pipe which supports the chipin a horizontal position. A 5 mm ball descended at 1 mm/sec until 5 gresistance was sensed, then it continued 30 mm and the force ofresistance was recorded as the chip bent and fractured. A StableMicrosystems Audio Envelope Detector was used to record the soundproduced during fracture.

To demonstrate the crispness/crunch of various snack products,representative samples were analyzed to measure the force required andacoustic levels resulting from fracturing chips. The analysis methodsconsisted of testing samples of chips listed in Table 3 below, labeled Athrough M, with samples A, B, C, D, L and M being produced in accordanceto the present invention as described in examples 28, 24, 25, 26, 27 and5 respectively, with retail samples E, F, G, H, I J, and K purchased ata local grocery store in Lincoln, Nebr. Representative chips wereselected from each sample, handled, and analyzed in a consistent mannerto obtain the data presented in Tables 3, 4, 5 and 6.

From each sample of about 25 chips, 9 chips were selected for the test.The more uniform chips were selected for measurement, because chips werevariable in thickness and blistering. The nine selected chips werefractured and measurements were made of the force required to fractureeach chip as the probe broke each chip while moving toward the chip at auniform speed of 1 mm/second. Exponent software was used to generate aplot of force (Newtons) against distance (mm), and to determine (1) theinitial slope, which is Young's Modulus, as discussed above, (2) thepeak force required to fracture the chip and (3) peak loudness uponfracture of the chip. Excel Spreadsheet software was used to calculatemeans, standard deviation and coefficient of variation. Prior to thisobjective testing, samples A, B, C, D, L and M were all tasted and foundto be favorably crisp and crunchy and samples E through K weredetermined to be within the indicated shelf life on the originalpackage.

Graphs plotting force (N) against distance (mm) traveled by the probewere generated for each force measurement. Each of these plots depict aseries of increases in resistance to applied force as the chip bendsunder pressure from the probe just prior to fracture. The probe ismoving toward the chip at a constant velocity of 1 mm per second (1mm/sec). In each case, the increase in resistance to applied force isfollowed by a sudden drop in resistance to such force as the chipbreaks. In most cases, the chips fracture and break in a series offractures. The first fracture, however, is the focus for determining thepeak force required to fracture the chip. The peaks created in this way,characterize the chip's texture, i.e., how much does the chip resistbending before breaking, how far will it bend before breaking and atwhat distance and force does it break. These quantities ‘fingerprint’fracture properties and their crispness and crunchiness. The sudden lossin resistance (after the force peaks) is accompanied by a recorded soundevent since the chip is set vibrating by the sudden loss in deformationand stress. As noted above, typical graphs include 2 to 4 major forcepeaks and a corresponding number of sound peaks. The slope prior to eachpeak estimates the aforementioned Young's modulus, which is a goodestimate of crunchiness. Since the samples tested were all crisp, any ofthe chips with an average Young's modulus greater than 3.5 N/mm areclearly crisp. In accordance with the present invention, it ispreferable to product a snack food product with a Young's modulus ofabout 3.5, more preferably about 4.0, even more preferably 4.5, and evenmore preferably about 5.0 N/mm. It is also preferable to have a snackfood product that will fracture at about 12, preferable about 10 andmore preferably about 9 N of force applied to the chip so that the snackfood product is crunchy but does not require so much force so that ishurts to eat the product.

The results of testing are provided in Tables 3-6 below. The resultingsound levels listed in Table 5 below do not have units as they are arelative number.

TABLE 3 Mean average for greatest force, sound and initial Young'smodulus from the data presented in Tables 4-6. Force Young's Peak PeakModulus Sample (N) Sound (N/mm) A - Thin chip of the present invention3.95 4097 13.7 B - Wavy chip of the present invention 4.58 3744 8.5 C -Puffy chip of the present invention 6.65 5968 19.7 D - Thick chip of thepresent invention 7.12 4139 15.7 E - Lays ® Classic 3.19 927 5.7 F -Lays ® Fat Free with OLESTRA ™ 2.59 1142 4.2 G - Lays ® Kettle CookedChips 5.14 1616 10.8 H - Kettle ™ Chips (Kettle Brand) 7.45 1447 14.2I - Low Fat Kettle ™ Krisp 5.65 23229 9.9 J - Kettle ™ Brand Bakes 6.233886 10.2 K - Terra ® Yukon Gold 9.06 10513 18.3 L - Sweet potato chipsof the present 8.77 6943 18.9 invention M - Beet chips of the presentinvention 3.62 3758 7.3

TABLE 4 Maximum Force (N). % Coefficient REP1 REP2 REP3 REP4 REP5 REP6REP7 REP8 REP9 MEAN of Variation A 1.20 3.77 1.62 2.84 7.39 3.45 5.415.29 4.53 3.95 50% B 4.05 5.65 3.64 5.09 2.19 2.68 5.89 4.64 7.38 4.5836% C 7.47 6.78 2.99 8.60 8.55 4.63 5.51 8.04 7.30 6.65 29% D 8.14 8.057.11 7.76 4.86 6.38 10.37 7.63 3.79 7.12 27% E 2.29 5.03 2.54 2.35 3.925.96 1.52 2.51 2.60 3.19 46% F 2.77 1.74 2.19 2.54 1.97 2.80 4.32 2.312.71 2.59 29% G 4.65 4.30 4.88 3.56 6.44 4.21 4.51 5.81 7.89 5.14 26% H9.69 7.43 8.67 9.85 5.87 8.16 4.41 6.64 6.37 7.45 24% I 5.56 3.73 6.554.19 4.50 8.97 8.72 3.56 5.03 5.65 36% J 2.06 7.56 6.94 11.94 6.39 2.958.12 4.00 6.16 6.23 48% K 11.68 9.37 10.75 10.88 7.20 5.97 11.10 8.755.87 9.06 25% L 8.88 8.88 11.22 7.25 10.10 6.35 7.59 6.53 12.13 8.77 23%M 2.73 2.02 3.15 4.81 3.64 3.93 5.74 3.30 3.28 3.62 31%

TABLE 5 Loudness. % Coefficient REP1 REP2 REP3 REP4 REP5 REP6 REP7 REP8REP9 MEAN of Variation A 1587 4402 2229 2140 6902 4266 7714 4349 32874097 51% B 4427 3933 4247 4741 1728 3965 5592 2412 2656 3745 33% C 66187134 5599 7986 8598 5215 2246 5510 4813 5969 32% D 5211 4778 7179 47532436 4804 4158 2361 1577 4140 42% E 1293 915 634 583 1198 1432 875 633782 927 34% F 389 661 634 1264 1299 1284 2544 1202 1008 1143 55% G 22691030 880 1462 2242 810 1355 1825 2674 1616 42% H 1549 1877 819 1132 18391571 1181 1041 2020 1448 29% I 5558 4560 8370 1698 5257 7193 4318 34794537 4997 39% J 1538 2237 4534 5610 1539 4445 6575 4060 4441 3887 45% K506 1409 1175 1626 1136 935 630 938 1107 1051 33% L 7600 6965 1175 79095915 4004 8198 6015 4132 6944 34% M 2806 3791 2668 3527 3171 5403 62262593 3638 3758 33%

TABLE 6 Young's Modulus (N/mm). % Coefficient REP1 REP2 REP3 REP4 REP5REP6 REP7 REP8 REP9 MEAN of Variation A 11.3 18.0 22.2 5.8 6.5 16.0 11.815.6 16.5 13.7 39% B 11.3 8.5 9.6 4.5 5.0 10.6 6.9 8.0 12.4 8.5 32% C19.1 18.4 8.9 28.1 18.6 22.7 17.7 27.2 16.5 19.7 30% D 14.3 16.0 18.316.6 18.1 7.1 22.0 14.0 14.8 15.7 26% E 4.9 16.4 5.0 4.1 6.3 5.5 1.1 3.64.1 5.7 75% F 4.8 2.1 5.5 3.1 3.7 6.2 1.0 6.9 4.5 4.2 46% G 11.3 13.99.0 6.8 21.2 3.1 6.5 8.3 17.0 10.8 53% H 25.4 19.8 15.8 12.8 13.5 11.98.7 13.6 6.6 14.2 40% I 8.2 2.2 15.0 3.8 21.0 14.4 15.9 3.4 5.8 9.9 68%J 3.8 11.9 8.8 13.4 3.6 10.2 23.6 7.2 9.0 10.2 59% K 21.9 4.7 27.6 22.130.2 12.7 24.1 19.2 2.2 18.3 53% L 25.6 1.0 22.0 9.8 26.7 23.9 17.4 16.626.8 18.9 46% M 7.0 6.0 5.6 11.2 5.2 7.8 10.2 6.6 6.4 7.3 28%

Example 38: Frozen Chicken Nugget

The breaded food pieces, with an intrinsic fat content of about 7%, areexposed to an oil-water emulsion at a concentration of 51% oil for 3 minunder ambient conditions.

Takeup of the emulsion into the breaded food pieces is about 12% byweight.

Then the pieces—having an initial moisture content of about 65%, arecooked in a convection oven set at 350 degrees F. for 10 min and then at300 degrees F. for 5 mins.

The final oil content of the cooked pieces is about 13 wt-% and thefinal moisture content is about 45%.

Example 39: Calamari (Earls)

The breaded food pieces, with an intrinsic fat content of about 2%, areexposed to an oil-water emulsion at a concentration of 37% oil for 2 minunder ambient conditions.

Takeup of the emulsion into the breaded food pieces is about 12% byweight.

Then the pieces—having an initial moisture content of about 40%, arecooked in a convection oven set at 350 degrees F. for 10 min and then at300 degrees F. for 5 mins.

The final oil content of the cooked pieces is 10 wt-% and the finalmoisture content was 30%.

Example 40: Chili Chicken Cubes (Earls)

The breaded food pieces, with an intrinsic fat content of about 5%, areexposed to an oil-water emulsion at a concentration of 82% oil for 90seconds under ambient conditions.

Takeup of the emulsion into the breaded food pieces is about 10% byweight.

Then the pieces—having an initial moisture content of about 65%, iscooked in a convection oven set at 350 degrees F. for 13 min and then at300 degrees F. for 7 mins.

The final oil content of the cooked pieces is about 13 wt-% and thefinal moisture content was 50%.

Example 41: Chicken Tenders/Fingers (Earls)

The breaded food pieces, with an intrinsic fat content of about 6%, areexposed to an oil-water emulsion at a concentration of 47% oil for 10min under ambient conditions.

Takeup of the emulsion into the breaded food pieces is about 17% byweight.

Then the pieces—having an initial moisture content of about 58%, arecooked in a convection oven set at 350 degrees F. for 12 min and then at300 degrees F. for 6 mins.

The final oil content of the cooked pieces is about 15 wt-% and thefinal moisture content was 43%.

The patents, patent applications and other documents cited herein areincorporated by reference as though fully set forth. The term “about” isused to designate the uncertainly inherent in the measurement of theparameter that it modifies, as would be recognized by one skilled in therelevant art. While the processes and food products have been describedin conjunction with specific embodiments thereof, it is evident thatmany alternatives, modifications and variations will be apparent tothose skilled in the art in light of the foregoing description.Accordingly, it is intended to include all such alternatives,modifications and variations as set forth within the spirit and scope ofthe appended claims.

1. (canceled)
 2. A method of making a snack food product comprising, (a)providing a plurality of cut or shaped food pieces comprising a fruit ora vegetable; (b) exposing the food pieces to a solution comprising about0.1-5 wt % of one or more starch-reducing enzymes and about 0.1 to about5 wt % CaCl₂; (c) thereafter blanching the food pieces for a timesufficient to inactivate the enzymes and rinsing the food pieces withwater, wherein the food pieces have an initial moisture level after theblanching step; (d) applying an emulsion consisting essentially of oiland water, said emulsion comprising salt (NaCl), for a time sufficientto provide a predetermined amount of oil to the food pieces and so thatthe food pieces have an initial moisture level after applying theemulsion; (e) reducing the initial moisture level of the food pieces bycooking the food pieces in bulk in at least one oven or drier set at afirst temperature of about 325-450° F. for a first time period of about0.5-40 min. to reduce the initial moisture level to an intermediatemoisture level; and (f) cooking a bulk quantity of the intermediatemoisture food pieces in the one or more driers or ovens set at a secondtemperature of about 225-325° F. for a second time period of about 4-35minutes, wherein the second temperature is lower than the firsttemperature, wherein the food pieces are not cooked or fried in hot oil,to yield a snack food product having moisture level of about 0.2-20wt-%; and a fat content of up to about 35 wt-%, wherein the snack foodproduct exhibits one or more characteristics of a snack food productproduced by frying a food piece in oil wherein the characteristics areselected from the group consisting of texture, flavor, crispness,crunchiness, color and appearance.
 3. The method of claim 2, wherein instep (f), the food pieces are cooked at about 300-325° F.
 4. The methodof claim 3, wherein the food pieces are cooked in a dryer/oven providingan air velocity of about 500-10,000 feet per minute.
 5. The method ofclaim 2, wherein in step (e) the food pieces are cooked for a time ofabout 0.5 to about 14 minutes.
 6. The method of claim 2 wherein the foodpieces are cooked at about 350-400° F. in step (e)
 7. The method ofclaim 2, wherein step (f) comprises cooking the food pieces at atemperature of about 275-300° F. for a time of about 6 to about 12minutes.
 8. The method of claim 2, wherein the food pieces are cooledand stored at ambient, refrigeration or freezer conditions after thefood pieces are brought to the first temperature for the first timeperiod, and before the food pieces are brought to the second temperaturefor the second time period.
 9. The method of claim 2 wherein the foodpieces are exposed to a solution comprising one or more of amylase oramyloglucosidase.
 10. The method of claim 9 wherein in step (b) the foodpieces are exposed to the solution for a time of about 1 to about 3minutes.
 11. The method of claim 2, wherein the food pieces are cookedin at least one rotary drier or oven, at least one fluidized bed drieror oven or at least one microwave drier or oven.
 12. The method of claim2, wherein said food is selected from the group consisting of beets,zucchini, carrots, eggplant, apples, pears, bananas, rutabaga, plantain,taro, okra, onions, parsnips, yams, sweet potatoes, yucca, and potatoes.13. The method of claim 2, wherein said cut food pieces are slices,strips or sticks.
 14. The method of claim 26, wherein said blanchingcomprises a wet blanch.
 15. The method of claim 14, wherein said wetblanch comprises treating said cut food pieces in an aqueous solution ata temperature of about 140° F.-248° F., and for about 15 seconds toabout 10 minutes.
 16. The method of claim 2, wherein the emulsion issprayed onto the food pieces.
 17. The method of claim 16 wherein theemulsion comprises about 5-85 wt-% oil.
 18. The method of claim 2further comprises rinsing the food pieces with water and drying the foodpieces prior to applying the emulsion to the food pieces.
 19. The methodof claim 2, wherein the fat content of the snack food product is up toabout 15 wt-%.
 20. The method of claim 2 wherein the final moisturelevel is about 2-5 wt-%.
 21. The method of claim 2 wherein the piecesare fluidized in air by said at least one drier or oven in steps (e) or(f).
 22. The method of claim 2 wherein the snack food product has a fatcontent of less than about 0.5 wt-%.
 23. The method of claim 2 whereinthe intermediate moisture level is about 40-70%.
 24. A food productproduced by the process of claim
 2. 25. The method of claim 2 whereinthe emulsion does not contain an exogenous emulsifier or surfactant.